Production Guide

Production User Guide
Information in this document is furnished only under a Customer License Agreement or
non‐disclosure agreement, and may be used or copied only in accordance with the terms
of such agreement. The software described in this document is protected by copyright,
and may not be copied on any medium except as specifically authorized in the license or
non‐disclosure agreement.
This document is also protected by copyright, and may not be reproduced or transmitted,
in whole or in part, by any means, including photocopying, facsimile transmission, or
reduction to any electronic medium or machine‐readable form, without the express
written consent of Sage Software Inc.
© 2010 Sage Software, Inc. All rights reserved.
The Sage Software logo and the Sage Software product and service names mentioned
herein are registered trademarks or trademarks of Sage Software, Inc. or its affiliated
entities. Adobe and Adobe are registered trademarks of Adobe Systems, Incorporate.
Pervasive, Pervasive.SQL, Scalable SQL, and the Pervasive Software logo are trademarks
or registered trademarks of Pervasive Software. Microsoft, the Microsoft logo, MS, MS‐
DOS, FRx, Microsoft Excel, Windows and Windows NT are trademarks of Microsoft
Corporation. Crystal Reports is a registered trademark and technology of Business
Objects, SA. HMIS® is a registered trade and service mark of the NPCA. Other product
names are trademarks or registered trademarks of their respective owners.
2 Sage PFW
Contents
Preface
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 1: Introducing Production

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Concepts You Need to Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Production and Other Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2: Setting Up Production

Setting Up Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Setting up System Setup Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Application Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to Complete the Application Setup Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Description of Application Setup Options ‐ Application Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Decimal Places Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maximums Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Edit Report Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting Up Lot Tracking Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to Complete the Lot Tracking Configuration Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Description of Lot Tracking Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting Up Batch Ticket Boilerplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to Complete the Batch Ticket Boilerplate Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Description of Batch Ticket Boilerplate Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Defining the Batch Ticket Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to Complete the Batch Ticket Layout Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Description of Batch Ticket Layout Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Setting up Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
How to Complete the Scheduling Formula Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Description of Scheduling Formula Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Setting up Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
How to Complete the Responsibility Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Description of Responsibility Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 3: Using Production

Methods of Entering Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Creating/Updating Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
How to Enter Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Batch Entry Fields ‐ Batch Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Miscellaneous Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Costs Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Finished Goods tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Formula Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
By‐Products Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Q/C Results Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Printing Batch Tickets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Production User Guide i

How to Print Batch Tickets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Printing the Production Master Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
How to Print a Production Master Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Changing the Status of a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Placing Production Orders on Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Activating Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Committing Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assigning Lot Numbers for Raw Material Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Uncommiting Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Requisitioning Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Automatic Posting of Production Transactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Canceling Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Closing Production Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Printing a Batch Edit Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Closing Batches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Partially Closing Batches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Scheduling Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Generating a Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Generating a Schedule Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Correcting the Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Creating Batches From the Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Purging Schedule Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Chapter 4: Generating Reports and Listings

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Batch in Process Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Committed Batch Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Container Usage Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Container Where Used in Process Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Critical Materials Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Finished Good Lot Explosion Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Finished Goods In Process Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Finished Goods Production Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Formula Production Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Lot Recall Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Material Lot Number Explosion Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Material Variance Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Material Where Used In Process Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Print Pick List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Production Cost Summary Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Production History Report (Detailed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Production History Report (Summary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Raw Material Usage Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Bill‐Of‐Materials Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Finished Goods Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Formula Line Items Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
History, Bill‐Of‐Materials Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
History, Finished Goods Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
History, Formula Line Items Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
History, Lot Numbers Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
History, Production Masters Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
History, Q/C Results Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
History, Transactions Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
ii Sage PFW
Lot Numbers Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Production Masters Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Q/C Results Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Responsibility Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Scheduling Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Appendix A: Production Data Files

Data File List and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Production User Guide iii

iv Sage PFW
Preface
Introduction
Sage PFW ERP is a suite of software applications that provide accounting, business
operation, process manufacturing and decision‐making functions for your organization.
Production is one of the many applications available in the Sage PFW process
manufacturing applications. The Production application provides a powerful and flexible
set of features that provides accounting, business operation, and decision‐making
functions for your organization.
About this user guide

This user guide contains information on how to use Production to easily enter and process
your production orders (also known as batch tickets), from start to finish.
Prerequisite knowledge
This user guide is based on the assumption that you have some accounting and
manufacturing knowledge. It does not attempt to teach accounting or manufacturing, but
rather describes how to implement the Sage PFW applications.
It is also assumed that you have some working knowledge of personal computers
operating in a network environment and a familiarity with Windows.
If you are new to Sage PFW, you should familiarize yourself with the operating
procedures described in the System Basics User Guide.
Related Documentation
The following publications provide additional information on using Sage PFW.
Document Name Description

System Management This user guide provides information on installing Sage PFW, as well
as setting up the appropriate system-level files and options to
enable users to access and use the system. It is intended for your
company’s System Administrator.
System Basics This user guide introduces the basic concepts common to all
Sage PFW applications; including forms, features, keyboard com-
mand keys, and common methods for entering data, viewing
data, generating and printing reports, and viewing online Help
and user guides.
Application User There is a separate user guide for each Sage PFW application pro-
Guides viding the specific instructions for processing data in that applica-
tion.
All Sage PFW user guides are provided online and may be
accessed from the Help menu. To view this information, start Sage
PFW, choose the User Guides item from the Help menu, and
choose the desired user guide to be viewed.
Production User Guide 1

Preface
Document Name Description

Online Help Each application contains online Help which provides information
on specific windows and fields. The user guides and online Help
are designed to be used in conjunction with one another.
Database Reference This guide contains the data file layouts for the Sage PFW applica-
Guide tions.
2 Sage PFW
Chapter 1:
Chapter 1: Introducing
Introducing Production
Production
Introduction
This chapter includes a brief description of the features, processes, and interfaces
available in Production.
In this chapter
This chapter contains the following topics:
Topic Page
Features 4
Concepts You Need to Know 7
Production and Other Applications 11

Features
Introduction
Production can make the difference between merely surviving and thriving in the highly
competitive process manufacturing industry. Powerful automation capabilities and
flexible options help expedite production scheduling, simplify batch sizing, improve the
accuracy of inventory and costing functions and generate real time information faster and
easier than ever before. Capitalize on the power and versatility of Production and
streamline your operations for success.
The most important function of the Production application is allowing you to easily enter
and process your production orders (also known as batch tickets), from start to finish.
You will have all of your current and historical production data available to assist you in
production control and customer order processing. The Production application is the
central processing unit, receiving data from the Formulas, Inventory Pro, Order Entry Pro
and Material Requirements Planning (MRP) applications, adjusting material quantities in
Inventory Pro, and tracking production costs. Then, Production automatically updates
your finished goodsʹ Last Cost and Average Cost data fields, in your Inventory Pro ‐
Location (INLOC) file.
It will also provide much useful information about your production operations, such as
cost data, and the actual amount of materials used, compared to the amount that was
required by your formulas.
Production will help you to perform the following tasks:
• Calculate batch sizes to match customer orders, or other criteria
• Print batch tickets
• Track the status of each batch in process
• Provide actual inventory usage
• Provide production cost data
• Optionally require lot tracking of certain finished goods
• Schedule batches in advance
• Track quality control test results
• Maintain historical records
• Generate useful reports
Description of Features
Batch Sizing
Batches can be sized automatically by weight, volume, finished goods ordered,
percentage of the master formula, premix quantity, or availability of one or all ingredients
from your inventory. Formula component quantities can be viewed and printed by
weight, volume, or any other units of measure that you define.
4 Sage PFW
Batch Status
Inventory tracking, batch scheduling, and production control are all improved with the
Production
Production applicationʹs multiple batch statuses, which means that individual materials
and finished goods can have different statuses on the same batch ticket. The statuses are
New, Committed, Hold, X (canceled), Requisitioned and Finished Customized Batch
Ticket Layout
Using Crystal Reports, you can customize the batch‐ticket layout to suit your companyʹs
needs. Batch tickets can be set up to include lot numbers and bill of materials items,
material quantities in various units of measure, whether to include or omit material
descriptions, and so on. Then, you can print a single batch ticket, a range of tickets by
batch number, all tickets scheduled to begin on a specified date (or range of dates), by
production status, responsibility, or simply print all unprinted tickets.
Inventory Usage and Cost Data

Production tracks information on material and container quantities required versus what
was actually used in a batch, giving you an accurate picture of usage, costs, and variance.
Highly flexible methods for labor and overhead costing help determine precise finished
goods costs.
Lot Tracking
The Production application automatically tracks raw material and finished good lot
numbers, bin numbers, and serial ship container codes (SSCCs) throughout the
production cycle, and allows multiple lot numbers to be used for a single material
requirement. A comprehensive lot number tracking history is maintained, so you can
always determine which raw material lots were used in which of your products, and to
whom those products were shipped. Lot‐related reports include the Material Lot Number
Explosion Report and Finished Goods Lot Number Explosion Report, which allow you to
trace lots from either end of the production cycle.
Scheduling
Batches can be scheduled automatically based on customer orders posted in Order Entry
Pro, or based on minimum stock levels and other methods, which you can define with
simple scheduling formulas.
Production History
Production maintains detailed batch history information including actual usage of
materials, quality control test results, batch number, customer, specific gravity, actual
yield, material costs, labor costs, overhead costs, and total costs. This information is
provided on a number of useful reports and is also used by other applications.
Quality Control
Quality control (Q/C) test descriptions and target values that were attached to the master
formula in the Formulas application, and test results entered during production are
maintained for each batch in process, and in batch history. This data can (optionally) be
printed on your batch tickets.

Useful Reports
The Production application keeps you informed with instant access to view or print the
following reports. Each report is explained in detail in the chapter of this manual entitled
Production Reporting.
• Batch Edit Report
• Batches In Process Report
• Committed Batch Report
• Container Usage Report
• Container Where Used In Process Report
• Critical Materials Report
• Finished Good Lot Number Explosion Report
• Finished Goods In Process Report
• Finished Goods Production Report
• Formula Production Report
• Lot Recall Report
• Material Lot Number Explosion Report
• Material Variance Report
• Material Where Used In Process Report
• Print Batch Ticket
• Print Pick List
• Production Cost Summary
• Production History (Summary and Detailed) Reports
• Production Master Report
• Raw Material Usage Report
• Schedule Report
6 Sage PFW
Concepts You Need to Know
Production
Batch Ticket
A batch ticket, or production order, is the document that authorizes the use of specific raw
materials, labor and processes to produce a product. The printed batch ticket documents
the materials and quantities to be used and provides written instructions to
manufacturing personnel. A batch ticket may be printed at any time after it has been
created and before it has been closed.
The batch ticket is divided into four sections, as described below. You can define the
general content of each section using the Production Batch Ticket Layout options.
1. The first section of the batch ticket provides a general description of the production job
and may include the batch number, date, customer name, description of the product, and
so forth.
2. The second section of the batch ticket contains data from the master formula; primarily
material specifications and manufacturing instructions. It may exceed the length of one
page, depending on the number of materials and instructions in the formula. For each
material listed, the quantity to be used is specified, and its inventory location may also be
listed, if you have defined multiple inventory locations. If the material is tracked by lot
number, you may include a space on the batch ticket where the line operator can enter the
lot number(s) from which materials were used.
3. The third section of the batch ticket contains information about the finished goods
ordered. You can also select to print the bill‐of‐materials requirements attached to the fin‐
ished goods and/or the containers, if you wish.
4. The fourth and final section of the batch ticket contains the Q/C test target values, along
with spaces to write in Q/C test results. Another option available in the Production Appli‐
cation Setup option is to have the Q/C target values copied to the Test Results field. This
data will not be printed on the batch ticket, but when the order is closed, the data will
appear in Production history reports.
Production Lot Numbers

You can automatically assign lot numbers to your finished goods, if you like. If you
choose this option, the auto‐assigned batch number is inserted into the Lot Number field
of the In‐Stock Lot Number (APSERIAL) file. The option to have batch numbers assigned
as lot numbers is selected through the Production Lot Tracking Configuration File
Maintenance option.
Note: You can enter lot numbers for finished goods manually, if you prefer, any time
after you enter the finished goods to be produced, or just before you close the batch
ticket.

Lot Strength Factor

Raw material lots can be assigned a strength factor. If your company does not purchase or
manufacture materials where lot strength is a consideration, you can safely ignore this
feature, since all lot strengths default to 1 (100 percent) unless you manually specify a
different value. Note that lot strength is expressed in decimal increments from zero to one,
where .5 would be equal to 50 percent, or one‐half of the nominal lot strength.
All lot strengths will default to 1 when they are recorded in the In‐Stock Lot Number
(APSERIAL) file. If a specific lot is tested and found to have a lot strength factor other than
1, you can enter the lot strength through the Inventory Pro In‐Stock Lot Number file
maintenance. When this particular lot is selected when committing the item to
production, the correct quantity from on‐hand inventory is automatically defaulted.
Note: If you use lot‐strength factors, you must have selected the Assign Lots During
Commit field in the Production application Application Setup option. This allows you
to assign lots during the Commit Order option. This option is automatically selected
when you install the Production application.
If you do not use lot‐strength factors in your business, you may wish to unselect this
checkbox so that you do not have to select material lots until the item is requisitioned or
closed. This option is explained further in Chapter 2 of this manual, which is entitled
Setting Up Production.
Restricting Formulas and Materials

There are two options, which allow you the flexibility of preventing certain statuses of
formulas and/or raw materials from being used in production. These options are set up
through the Production applicationʹs Application Setup option.
Formula Statuses Not Allowed in Production

You may specify up to 10 formula statuses to be not allowed in Production. Formulas that
have a status, which you have entered in this option will not be available for use in
Production.
The formula status keys and their descriptions must have previously been set up through
Formulas File Maintenance options. For example, you may wish to prevent formulas with
a status of H (for Hold) or O (for Obsolete) from being used in Production.
Inventory Statuses Not Allowed in Production

You may specify up to 10 inventory statuses to be not allowed in Production. Raw
materials that have a status, which you have entered in this option will not be available
for use in Production.
The inventory status keys and their descriptions must have previously been set up
through Inventory Pro File Maintenance options. For example, you may wish to prevent
materials with a status of Hold or Experimental from being used in Production.
8 Sage PFW
Production Order Status
The current processing level or status of each production order is indicated by a
Production
production status code. Refer to the following table to see the order in which statuses may
be changed.
Production Order Status
The following table displays the different statuses.
Status Can Be Changed To
New Hold, Committed, X (canceled), Requisi‐
tioned, Finished, or Closed
Committed New, X (canceled), Hold, Requisitioned,
Finished, or Closed
Requisitioned Hold, Finished, or Closed
Finished Hold or Done (closed)
Done (Closed) or Cannot be changed
X (Canceled)
Note: Hold is a special, temporary status. An order can be placed on Hold from any
status except Canceled. When the order is activated, the Hold status is removed, and
the order will revert to the status it had before it was placed on Hold.
The status hierarchy, that is, which status takes precedence over the others, is detailed in
the following chart. The status of the production order is determined by the highest
finished good or formula line‐item status, from New to Requisition. Notice that orders
which are placed on Hold must be activated before they can be changed to any other
status, or Un‐committed (reduced from Committed to New). Once the status of any line
item is Requisitioned (removed from inventory), then the order cannot be canceled, or its
status reduced, although it can be placed on Hold, temporarily. You may want to review
all orders that are placed on hold, in order to monitor the cause of delays in production.
Variance
Variance is supported for standard costs associated with the formula line item screen.
When a batch is closed, the total raw material, labor, and overhead cost of each line is
calculated and compared with the costs calculated based on the quantity required for the
line. Any differences are written as variances. The raw material variance account is taken
from the Inventory Class (INCLASS) file. The labor variance account is taken from the
Formula Additional Cost (FMADDCST) file. The overhead variance account is taken from
the Overhead Cost (FMOVERHD) file.
By-Product Costing
If a Formula has a By‐Product, what is the best way to setup costs to be used in
Production? The cost of the by‐products is subtracted from the total cost of the production
batch, while the Overhead costs of the by‐products is added to the total cost of the batch.

Setting up By-Products
1. Select Inventory Pro/Item Entry. Enter the by‐product item and select Standard Cost as
the cost method. Since there is not a by product type, it must be added to a formula on the
By‐Product tab. Select the Location tab and enter location for by‐product. Select Price and
Cost tab and enter the by‐products standard cost.
2. Select Formulas/Formula Processing/Formula Entry and select the formula producing
the by‐product. Go to the By‐Products tab and enter the by‐product and location and
quantity for your standard formula size.
3. Select Production/Select Batch Entry. When entering a new batch, the by‐product set up
in the Formulas module automatically populates By‐Products Tab for the batch. When
sizing the batch ticket, there is a check box to automatically size the by‐products
proportionally with the batch. If you select this check box it is not necessary to enter the
quantity produced for the by‐product because the system automatically defaults to the
quantity ordered.
4. Once the batch is closed, the cost of the by‐product is subtracted from the total cost of
the production batch.
For example if 100 lbs of by‐product are produced at $1 standard cost. The total cost of the
by‐product is $100. Closing the batch reduces the total cost of the batch by the $100 (by‐
product cost). The total cost of the batch that is left over is distributed among the finished
goods produced.
Note: If you charge overhead on actual production by entering an overhead key for
the by‐product, in either formula entry or in the actual batch, the overhead is added to
the cost of the batch.
10 Sage PFW
Production and Other Applications
Production
Introduction
In order to use the Production application you must have previously installed and set up
the System Manager and System Manager Pro, Formulas, and the Inventory Pro
applications.
Inventory Pro
Production is fully interactive with Inventory Pro application. Production transactions
result in raw materials being committed to production and then relieved from inventory
as they are requisitioned, and finished goods are added to on‐hand quantities when
batches are closed.
Order Entry Pro

If you have installed Order Entry Pro, you can set up Productionʹs Scheduling option to
schedule production orders based on customer orders which have been entered in the
Order Entry Pro application.
MRP
If you have Material Requirements Planning (MRP), it can automatically schedule
production orders based on customer orders that have been entered in Order Entry Pro,
and/or minimum inventory requirements that you have established in Inventory Pro.
MRP will also schedule the production of intermediate formulas, if they will be required
in a top level formula that is scheduled for production.
MSDS
If you have MSDS, Production can provide data from batches in process, or from
Production history data, for printing the required material safety information.

12 Sage PFW
Chapter 2:
Setting Up Production
Introduction
This section describes the information that you must enter into the Production database
Chapter 2: Setting Up
before you can begin to use the Production application.
Production
In this chapter
Topic Page
Setting Up Production 14
Setting up System Setup Files 15
Setting up Scheduling 33
Setting up Responsibilities 36

Setting Up Production
Introduction
Before you using the Production application, you should do the following:
• Set up the System Setup files
• Set up the File Maintenance files
In this section
This section contains the following topics:
Topic Page
Application Setup 15
Setting Up Lot Tracking Configuration 22
Setting Up Batch Ticket Boilerplates 25
Defining the Batch Ticket Layout 27
How to Complete the Batch Ticket Layout Window 28
14 Sage PFW
Application Setup
Setting up System Setup Files
Description
Before you begin using the Production application, it is essential that you define how you
want the application to perform. The System Setup folder stores the configuration files
that you need to initially setup. These files are usually setup and then left alone as they
define how Production will process.
Production
Application Setup
This menu item allows you to enter the starting batch number, if you are just starting to
use Production, and review the applicationʹs configuration options, and the choices that
were supplied when you installed Production. You may want to change some of them to
best serve your companyʹs needs.
When Application Setup is selected from the business desktop, the Application Setup
window appears. There are three tabs for Application Setup. Default data exists on these
tabs that set up Production for the typical user. Each data field is explained in the
following section. Read the explanations so that you will understand their functions and
then perhaps you will want to change some of the settings to match your companyʹs sales‐
order practices.
Application Setup window

When you select Application Setup from the System Setup folder, the following screen
displays.

Tabs
The following is a description of the tabs on the Application Setup window:
Tab Description
Application Setup Define basic processing options for Production.
Decimal Places You can control the number of decimal places
to be used in Order Entry Pro.
Maximums You can determine the number of Finished
Goods per batch.
Edit Report You can select which options will present errors
or warnings on the edit report.
How to Complete the Application Setup Window

You set up Production by completing Application Setup.
Procedure
To complete the Application Setup window, do the following:
Step Action
1 Select Application Setup from the business desktop.

The Application Setup window appears.
2 Complete the tabs in the Application Setup window.
3 Select Save.
Need more information? Press F1.
Description of Application Setup Options - Application Setup Tab
Next batch number

When you install the Production application, this number is set to 1001. If you have an
existing batch‐number series, you can enter a different number for the next batch, and it
will be assigned automatically when you enter a new production order.
Note: Once set, this number should never be changed, since duplication could
damage data files. This number is automatically incremented each time you cre‐
ate a new production order.
16 Sage PFW
Description of Application Setup Options - Application Setup Tab
Track production history

This field is set to Yes when you install the Production application. This will cause all
transactions which occur in Production to be tracked.
Note: Production transactions are not the same as inventory transactions, and
have different type codes. Production transaction types are R, for items requisi‐
tioned from inventory, and P, for finished goods produced.
Inventory transactions, which are also used by the Purchasing Pro and Order
Entry Pro applications, have numerous types of transactions, which are defined in
your Inventory Pro Userʹs Guide.
Production
History tracking
If you selected Yes in the Track Production Transaction History field, above, then select
the history tracking method to be used, either Summary, Detailed, or None. If you select
Summary, only summary information will be tracked and stored.
Transfer blank Q/C results to history

This field is set to Yes to allow complete production orders with blank Q/C test results to
be transferred to the history files. If you select No, you will need to enter Q/C test results
before the batch is closed, for the results to transfer to the Production Q/C History file.
Inventory statuses not allowed in production

If there are some inventory statuses that you do not want used in Production, then enter
the single character key for those statuses here. Leave no spaces or commas between
characters. For example, you may not want statuses such as X (for eXperimental) or H (for
Hold) to be allowed in Production.
Formula statuses not allowed in production

If there are some formula statuses that you do not want used in Production, then enter the
single character key for those statuses here. Leave no spaces or punctuation between
characters. For example, you may not want statuses such as X (for eXperimental) or O (for
Obsolete) to be used in Production.
Transfer Q/C targets to results

This option defaults to No, and you must enter the quality control test results manually,
using the Production Daily Processing Q/C Result Maintenance option.
If you set this field to Yes, then the Q/C target values is copied to the Test Result fields at
the time you enter a master formula in a new production order. However, this data will
not be printed in the “Test Result” column on the batch ticket; which is left blank for the
line operator or test technician to fill in the actual results, when the test is performed. This
option is handy if a lot of your test target values are either “Yes” or “No.”
Note: You can select whether you wish Q/C test information to be printed on
your batch tickets, or not, in the Batch Ticket Layout options.

Assign lots during commit

This option defaults to Yes, which requires that you assign lots when you commit a
material item which requires lot‐tracking, instead of when you requisition it. If you set
this field to No, then lots will not be assigned until you requisition the materials.
Display standard / average / last cost

Select the costing method you would like displayed at the bottom of the production order
Line Item tab), in the COST/LB, COST/GAL and Total Cost fields. These costs are based on
the raw‐material costs from Inventory Pro and the labor and overhead costs from the
master formula, and calculated according to the size of the batch.
Base labor and overhead on usage/yield

Select if you would like total batch labor and overhead costs to be based on the total
quantities of materials used in the batch, or on the final batch yield.
Significant loss factors could play a role in labor and overhead costs, thus you would want
to take into account the extra cost by basing the labor and overhead costs on usage.
Update finished good on hand before close

Place a checkmark in this box to increase the finished good or intermediate material on‐
hand quantity field when the finished good line item is manually marked as F (Finished).
This allows you to sell lot‐tracked finished goods prior to completely closing the batch in
Production.
Decimal Places Tab
Decimal places
These five fields establish the default number of decimal places for the formulas. Enter the
desired number of decimal places for Price, Quantity, Cost, Amount, and Percent.
Remember that the report columns only permit fifteen numeric characters, including
commas and decimal points. Exceedingly long decimals places may affect the numbers
displayed in your reports.
Maximums Tab
Maximums
This field sets the maximum number of finished goods per batch. This is a user‐defined
number.
18 Sage PFW
Edit Report Tab
Edit Report Tab
Require Edit Report before Batch Close

This field allows you to determine if you want the system to prohibit the closing of a batch
until an error‐free Batch Edit Report has been generated. You can choose to:
• Require an error free edit report to be run prior to closing a batch.
• Display a warning message if the edit report has not been run. After the warning
messages displays, you can continue closing the batch.
• Close a batch with or without running an edit report.
Production
Require Edit Report before Requisition or Finish
This field allows you to determine if you want the system to prohibit the requisitioning or
finishing of a batch until an error‐free Batch Edit Report has been generated. You can
choose to:
• Require an error‐free edit report to be run prior to requisitioning or finishing a
batch.
• Display a warning message if the edit report has not been run. After the warning
messages displays, you can continue processing the batch.
• Requisition or finish a batch with or without running an edit report.
Verify Non-Lot Tracked Critical Materials

The Batch Edit Report always generates an error for Critical Materials if they are lot‐
tracked items. Errors or warnings are optional for non‐lot‐tracked items.
Formula
Verify Loss Constant per Batch Weight
You can set a limit in Formula Class so that when the Formula has a significant Loss
Constant, you can make sure the batch size is large enough so that there is a smaller
percentage of waste of your Raw Materials.
This option verifies that the loss constant is within your range and displays either a
warning, error or nothing.
If the total weight of Raw Materials used is (for example) 100 pounds, and the Formula
Loss Constant is 90 pounds, 90% of the Raw Materials is lost before you even started
mixing the batch. If the batch weight is 200 pounds on the other hand, then a 90 pound
Loss Constant is only 45% of the Batch weight.
Note: Maximum Loss percent is setup in Formula Class.

Verify Loss Factor
When you resize a Batch, you are prompted for the Formula Loss Factor and Loss
Constant, which can be changed to any value at that point, including zero.
This option verifies that the loss factor is within your range and displays either a warning,
error or nothing.
If a Formulaʹs Raw Material weight is 100 LB, the Loss Constant is 50 LB, and the Formula
Loss Factor is 50%, the batch weight will be recalculated by Batch Entryʹs “Size Batch”
option to 250 LB. The percentage Loss Factor gets calculated first, then the Loss Constant
is added to the result.
Note: Maximum Loss percent is specified in Formula Class.
Variance between Batch Weight and Order Weight
Batch Weight and Order Weight represent the total weight of the Raw Materials required
and the total weight of the Finished Goods ordered. The Production History Report
(Detailed) uses the terms “Total Material Used” and “Total Material Yield”. You can
control these variances two ways:
• Use this feature to make sure (for example) that the Batch Weight of 100 pounds is
producing at least 10 pounds of Finished Goods
• Use the Formula Loss Factor feature to specify (for example) a 90% Formula Loss Fac‐
tor, then set the maximum Formula Loss Factor in the Formulaʹs Class record to 90%.
Note: Maximum Variance percent is specified in Formula Class.
Finished Goods
Variance between Quantity Ordered and Produced
In most real‐world production, the quantity produced from a given weight of Raw
Materials is less than the projected amount, not more. In this case, you may want to know
if the quantity produced is significantly less than the quantity ordered. You may also
want to know if a partial Finished Good is produced, which might not be sellable.
Note: Maximum Variance percent is specified in Item Class.
Quantity Produced is Zero
When a Batch is created and Finished Goods are entered for the Batch, the Quantity
Produced always defaults to zero. If you leave this quantity set to zero, and the Close
Batch menu item automatically copies the Quantity Ordered value to Quantity Produced.
If you want the quantities automatically filled in, set this option to None or Warning.
If you want to fill in the Quantity Produced in Batch Entry, you may want to setup this
option as a Warning or Error so that the edit report notified if you forget to fill in the
quantity.
20 Sage PFW
Edit Report Tab
BOM Quantity Differs from Inventory BOM
BOM items and their respective quantities are sometimes difficult to ascertain manually
because the BOM quantity is multiplied by the Finished Goodʹs “each” quantity, and
because BOM items may have multiple levels of components where the quantities are
further multiplied at each additional level.
This option allows you to compare what would be the default BOM items and quantities
assigned automatically by Batch Entry, based on the Finished Good quantities, to the
actual BOM items and quantities that occur in the Batch. This option also checks for BOM
items specified in Inventory Pro that are missing from the Batch, BOM items included in
the Batch that arenʹt specified in Inventory Pro, and BOM item quantities in the Batch that
donʹt match quantities specified in Inventory Pro. Also, the BOM quantities are calculated
from the Finished Good Quantity Produced (if non‐zero), otherwise the BOM quantities
Production
are calculated from the Finished Good Quantity Ordered.
Finished Good Formula differs from Batch Formula
In Batch Entry, the Finished Goods lookup displays a list of all finished goods, regardless
of the selected formula. You may have Finished Goods with formulas that are different
from the batch formulas, but these formulas may be so closely related that you can
produce that Finished Good from a Batch whose Formula doesnʹt match the Finished
Good Formula. If this is the case, you will probably want to set this option to Warning, so
that you are notified when a different formula is used. If you set up this option as an
Error, you cannot close the Batch when the Formulas donʹt match.
If this option is setup as an Error, the lookup found in Batch Entry on the Finished Goods
tab is restricted to show only the Finished Good keys matching the Batch Formula. If this
option is setup as a Warning or None, the lookup displays all Finished Good keys.
Note: When multiple Finished Goods are entered for one Batch, there may be
some Finished Good Formulas that match the Batch Formula, and some that
donʹt.
Raw Materials
Variance between Quantity Required and Used
Similar to Finished Good discrepancies, a significant difference between the quantity
required and used could have a detrimental effect on the Finished Formula if the wrong
quantities are used.
Note: Maximum Variance percent is specified in Item Class.
Verify Loss Factor
When a new Batch is created, the Raw Material Loss factors are pre‐calculated into the
Batch weight, and the Formula factors are calculated only when you resize the Batch.
When you resize a Batch, you are prompted for the Formula Loss Factor and Loss
Constant, which can be changed to any value at that point, including zero.
This option verifies that the loss factor is within your range and displays either a warning,
error or nothing.

Note: Maximum Loss percent is specified in Item Class.
Finished Goods with BOM’s used as Raw Materials
If a Finished Good that uses a costly container (i.e. a stainless steel drum) is used as a Raw
Material in a batch, and the batch consumes only the contents of that container, not the
container itself. When you close the batch, the full Inventory cost of the Finished Good is
charged, including the cost of the container. It is recommended to use the Raw Material
Intermediate portion of the Finished Good as a line item in the Batch, rather than use the
Finished Good key that includes the container.
Note: If the container is not disposed of, someone will want to clean it and put it
back into Inventory, which would require an adjustment transaction to credit Pro‐
duction and debit Inventory.
If you choose not to create an Intermediate key for this purpose you can set this option to
notify you of the leftover containers.
Setting Up Lot Tracking Configuration

You can begin using Production without changing the lot tracking default settings
supplied, even if you have some raw materials or finished goods which require lot
tracking. However, you might want to read the following description of the Lot Tracking
Configuration option, in case you may want to further customize your use of lot tracking.
If any of your raw materials have been defined in the Inventory Pro application as
requiring lot tracking, they will have been given lot numbers when they were received.
When those items (including bill‐of‐materials items) are requisitioned (or Committed, if
you chose that option), you will be prompted to assign one or more of these lot numbers
from which to relieve the required raw material. A pop‐up window will allow you to
preview all available lots for a particular item, along with the quantity available from each
lot. This information is obtained from the A/P In‐Stock Lot Number (APSERIAL) file.
You can automatically relieve inventory from available lots, or you can enter the quantity
manually that you wish to relieve from one or more lots. As lots are selected, the quantity
required is subtracted from the quantity available from that lot. If the entire balance of a
lot is used, the lot record will be removed from the APSERIAL file.
22 Sage PFW
How to Complete the Lot Tracking Configuration Window
Lot Tracking Configuration window

When you select Lot Tracking Configuration from the System Setup folder, the following
screen displays.
Production
How to Complete the Lot Tracking Configuration Window
You set up Production by completing Lot Tracking Configuration.
Procedure
To complete the Lot Tracking Configuration window, do the following:
Step Action
1 Select Lot Tracking Configuration from the business

desktop. The Lot Tracking Configuration window
appears.
2 Complete the tabs in the Lot Tracking Configuration
window.
3 Select Save.
Description of Lot Tracking Configuration Options
Require Quarantine Date

Select Yes to indicate that a lot must have a valid quarantine date and be past that date
before being available for use in Production. If you have selected Yes and there is no
quarantine date entered, or if the quarantine date falls on or after the current processing
date, the lot in question will not be available in Production. If you selected No, then this
option is ignored.

Require Expiration Date

Select Yes to indicate that a lot must have a valid expiration date which is not on or before
the current processing date, or it will not be available for use in Production. If you have
selected Yes and there is no expiration date entered, or if the expiration date falls before
the current processing date, the lot in question will not be available in Production. If you
selected No, this option is ignored.
Require Passed Q/C Status

Select Yes if you would like to specify that a lot must have passed specified quality control
tests in receiving inspection before being available for use in Production. If you Select Yes,
lots will only be available in Production if they have a Q/C Status of P (for Passed).
Statuses of F (for Failed) or N (for Not tested) will not be available until their status is
changed to P (for Passed). If you enter N (for No), this option is ignored.
Require Lot Status

Select whether or not you would like to restrict the availability of lots in Production based
on their lot status. If you select Yes, a lot must have a valid lot status entered before it can
be used in a batch. Lots which have a blank Lot Status field, or have a status which does
not match any of those which you have specified in the following field, will not be
available in Production.
Lot Statuses Allowed In Production

You may specify up to 20 lot statuses to allow in Production. If you have set the Require
Lot Status field, above, to Yes, then each lot must have a non‐blank lot status which is
included in this field before it can be used in Production. Lots which have a blank status
or do not match any of the statuses you have entered here will not be available for use in
Production.
Note: Simply enter the single‐character lot statuses one after another. Do not
leave any blank spaces and do not use any punctuation. Lot statuses must have
been previously defined through the Inventory Pro ‐Inventory Status Description
menu item. A lot status is assigned to a lot via Inventory Pro Q/C Lot No. Result
maintenance option.
Sequence Lots By Expiration/purchase/quarantine Date

Select Expiration if you would like the lots displayed in the order of their expiration dates,
Purchase dates, or Quarantine dates. This option allows you to sequence the order of lot
numbers when they are displayed for selection. It also defines the order in which lot
numbers will be used if you want to automatically assign lots when materials are
requisitioned.
Automatically Assign Lots

Select whether or not you would like to automatically assign sufficient quantities from
available lots to satisfy the requirements of the batch. The quantity assigned will be based
upon on‐hand availability and lot strength.
24 Sage PFW
Setting Up Batch Ticket Boilerplates
Assign Batch Number To Completed Lots

If you select Yes, the batch number is automatically assigned as the lot number to any
finished goods which have a blank lot number.
Calculate Lot Expiration Date

If you select Yes, the lot expiration date is calculated for all completed finished good lots
based on the earliest expiration date of all of the lot tracked raw materials in the batch.
Setting Up Batch Ticket Boilerplates
Production
The Batch Ticket Boilerplates option allow you to print standard manufacturing
instructions (boilerplate paragraphs) on all of your batch tickets, or on some of your batch
tickets. For example, you could define special boilerplates which will appear on all batch
tickets which include hazardous materials.
This option is not mandatory for beginning to use the Production application for printing
batch tickets. Read the following description, and then come back to this option when you
wish to further customize your batch tickets.
Note: Before you can enter boilerplate keys in this option, the boilerplate text
must have been entered and assigned a key through the Formulas application
Boilerplates Entry file maintenance menu item. Boilerplates are primarily used to
enter standard manufacturing instructions in your formulas, which are then
printed on a batch ticket among the formula line items.
In addition to these manufacturing instructions, other standard information which you
want to appear on all of your batch tickets (or a special layout for a few batch tickets) can
be set up by entering boilerplate keys, attributes and location, using this option. Then, the
boilerplate text that you have entered just for this purpose will automatically be printed in
one or more of the four sections of the batch ticket.
The batch ticket is divided into four sections. You can enter a boilerplate key to print
standard text following one or more of the four sections. Typically these will cover safety
information or handling instructions that are standard for a whole class of your products.
Two different boilerplate layouts can be set up to print your batch tickets; using the same
or different boilerplate keys.

Batch Ticket Boilerplate window

When you select Batch Ticket Boilerplate from the System Setup folder, the following
screen displays.
How to Complete the Batch Ticket Boilerplate Window

You set up Production by completing Batch Ticket Boilerplate.
Procedure
To complete the Batch Ticket Boilerplate window, do the following:
Step Action
1 Select Batch Ticket Boilerplate from the business desk-

top. The Batch Ticket Boilerplate window appears.
2 Complete the tabs in the Batch Ticket Boilerplate win-
dow.
3 Select Save.
Description of Batch Ticket Boilerplate Options
#1-4 Boilerplate Key

Enter the key of the boilerplate that you wish to appear on your batch tickets.
After Section n
Enter the section number that you would like this boilerplate to follow.
26 Sage PFW
Defining the Batch Ticket Layout
Column Width
Enter the number of columns across the page that you would like this boilerplate to
occupy. Remember that 8.5 x 11‐inch paper is 80 columns wide and 11 x 14‐inch paper is
132 columns wide. If you do not want a boilerplate to appear, enter 0 (zero).
Defining the Batch Ticket Layout

A basic Batch Ticket Layout has been set up for you, when you installed the Production
application. This will allow you to begin printing batch tickets using the standard layout.
However, you should take a look at this option, in the event that you might wish to set up
a custom batch ticket layout to suit your companyʹs needs. In addition, you can further
Production
define how the batch ticket is laid out through Crystal reports.
The Batch Ticket consists of four sections:
• Section 1 includes general information about the batch, such as the formula key,
description, start and completion dates, responsibility key, production order status,
notes, customer key and description, specific gravity, and output formula key.
• Section 2 includes manufacturing instructions, both standard (boilerplate) text that
you have previously defined and/or literal text, plus the item key, line status, location
key, description, weight or volume required, alternate units of measure, HMIS codes,
and overhead key.
• Section 3 contains quality control test descriptions, target values and test results.
• Section 4 contains finished goods information, including bill of materials.
Note: Sections 3 and 4 can be printed on the same page as formula line‐item data,
(if there is room), or you can select in the Batch Ticket Layout options to have one
or both of those sections start printing on their own page of the batch ticket, or to
not print at all.

Batch Ticket Layout window

When you select Batch Ticket Layout from the System Setup folder, the following screen
displays.
How to Complete the Batch Ticket Layout Window

You set up Production by completing Batch Ticket Layout.
Procedure
To complete the Batch Ticket Layout window, do the following:
Step Action
1 Select Batch Ticket Layout from the business desktop.

The Batch Ticket Layout window appears.
2 Complete the tabs in the Batch Ticket Layout window.
3 Select Save.
Description of Batch Ticket Layout Options
Formula and Production Order Description through Line

Enter the number of formula notes lines that you would like to appear on every batch
ticket or production order. Enter 0 (zero) if you do not want any formula notes lines to
appear.
28 Sage PFW
Formula and Production Order Notes Through Line

Enter the number of production order notes that you would like to appear on every batch
ticket. Enter 0 (zero) if you do not want any production order notes description lines to
appear.
Weight Column Format

For inventory items that you have designated (in Inventory Pro) to be measured by
weight, the weight required for each line item prints in the Pounds column on the batch
ticket, and any quantity less than one pound will be printed in the format that you choose
here. Select either Decimal, Fractions, or Ounces.
Production
The weight column will be labeled Kilos if you chose Metric in the System Manager
Company Defaults. Only the Decimal setting in this field is appropriate for metric
quantities.
Volume Column Format

For inventory items that you have designated (in Inventory Pro) to be measured by
volume, the volume required prints for each line item in the Gallons column on the batch
ticket, and any quantity less than one gallon will be printed in the format that you choose
here. Select Decimal, Fractions, or fluid Ounces).
The volume column will be labeled Liters if you chose Metric in the System Manager
Company Defaults. Only the Decimal setting in this field is appropriate for metric
quantities.
Boilerplate /literal Text On

Select Own Line if you want to display your boilerplates and literal instructions on their
own line horizontally across the batch ticket. Select Description Line if you want them to
appear in the defined description column. Care must be taken to ensure that your
boilerplates and literal instructions are readable if you select them to be placed in the
description column. Use the Lookup button next to the field to make your selection.
Use Rounding For Weight Quantities

Select Yes to indicate that you would like the weight quantities rounded to the nearest
whole unit on the batch ticket. Leave this checkbox unselected if you would like quantities
less than one unit of weight to be printed as specified in the Weight Column Format field,
above.
Use Rounding For Volume Quantities

Select Yes to indicate that you would like the volume quantities rounded to the nearest
less than one volume unit to be printed as specified in the Volume Column Format field,
above.

Use Rounding For Alternate Unit Quantities

Select Yes to indicate that you would like the QTY REQʹD field rounded to the nearest
less than one alternate unit to be printed as specified in the Alternate Unit Format field,
below.
Use Rounding For Labor Quantities

Select Yes to indicate that you would like the labor cost quantities rounded to the nearest
whole unit on the batch ticket. Leave this checkbox unselected if you would like labor
quantities printed to the number of decimal places that you specified in the System
Manager Company Defaults option.
Note: Quantities of less than 15 will not be rounded, since a fractional part of a
small quantity can be a significant percentage.
Alternate Unit Format

If you have set up Alternate Units of Measure, and attached them to your raw materials,
you can have the line‐item quantities printed on the batch ticket in one of four different
ways. These alternate unit quantities will be printed on the batch ticket in addition to the
standard weight or volume quantities, which have their own column.
1. Print the alternate unit of measure, if selected during order entry.
The quantity required for each material line item is printed on the batch ticket in standard
units of either weight or volume, whichever you assigned to the item in Inventory Pro. A
column for each is provided on Batch Ticket Layout #1, which is furnished with the
Production application. These columns are labeled Gallons and Pounds (or Liters and
Kilos, if you chose the metric measurement system in System Manager Company Defaults
option). The quantity required will be entered in one of these two columns in the standard
units of weight or volume.
If you enter 1 in this field, and you have attached an alternate unit of measure to the item
(in Inventory Pro), and you toggled the line item to that unit of measure when creating the
batch ticket, then the name of that alternate unit of measure will be printed in the Unit
column and the converted quantity will be printed in the QTY REQʹD column of the batch
ticket. These columns are also set up for you in Batch Ticket Layout #1.
For example, if the alternate unit of measure selected during order entry for an item is
Kilo (defined as 2.2 pounds each), then a requirement for 81 pounds of a material would
be printed on the batch ticket as follows:
Line Gallons Item Key Pounds Qty Req'd Unit

1 IRNOX 81.000 36.8 KILO
Note: The Item Description column has been omitted from these examples, in
order to show the Qty Reqʹd and alternate Unit columns as they are printed on the
batch ticket.
30 Sage PFW
2. Use best fit of all alternate units of measure attached to the item, whether selected or
not.
If you enter 2 in this field, the best fit is queried based on the minimum and maximum
significant amounts that you have defined, when you have more than one alternate unit of
measure attached to an item. If a fit is found (i.e., the quantity required is between the
minimum and maximum significant amounts for that alternate unit), then that alternate
unit of measure will be printed. If a suitable alternate unit is not found, the Qty Reqʹd and
Unit columns will be used to print the quantity required in the standard units of either
weight or volume.
For example, in addition to the Kilo alternate unit shown in the example above, suppose
you have defined an alternate unit of Gram, equivalent to .0022 pounds, with the
maximum significant amount of 2.2 pounds. The minimum significant amount of the
Production
alternate unit Kilo was set to 2.2 pounds, so that any requirements of less than 2.2 pounds
(equivalent to one Kilo) will be printed in Grams, and conversely, any requirement
greater than 2.2 pounds will be printed in Kilos, as in the example, above. If you enter 2 in
this field, and you have a requirement for 1.867 pounds of an item, your batch ticket will
print the quantity required as follows:
Line Gallons Item Key Pounds Qty Req'd Unit

2 CUOX 1.867 848.69 GRAM
3. Same as option #2 except round the alternate unit of measure quantity and show the
remainder in standard weight or volume units.
To avoid having to figure out how to convert the remainder of a partial alternate unit of
measure (.8 KILO in the example #1, above), you can use this option to convert any partial
units to the standard unit of measure. If you enter 3 in this field, the requirement for 81
pounds of the item IRNOX will be shown as follows:
Line Gallons Item Key Pounds Qty Req'd

1 IRNOX 81.000 36 KILO + 1.76 LB
4. Same as #3 except the remainder will be displayed in the next available alternate unit
of measure, if possible.
If you enter 4 in this field, the requirement for 81 pounds of IRNOX will be printed on the
batch ticket as follows:
Line Gallons Item Key Pounds Qty Req'd

1 IRNOX 81.000 36 KILO + 363.2 GR
Note that the remainder alternate unit identification (GRAM) was truncated because the
Qty Reqʹd column was set to contain only 19 characters.
Include Q/C Specifications On

Select Same Page to include quality control information on the same page (or last page) of
the formula line item information. Select Own Page to print the Q/C information starting
on a page by itself. Select None if you do not want Q/C data printed on the batch ticket at
all.

Include Finished Good Info On

Select Same Page to include the finished goods information on the same page (or the last
page) of the rest of the batch ticket information. Select Own Page to print the finished
goods information starting on a page by itself. Select None if you do not want finished
goods information printed on the batch ticket at all.
Include Finished Goods Bills-of-Materials

Select Yes to include the bills‐of‐materials items for the finished goods ordered on the
batch ticket. This will print the item key and description plus quantity required for the
container(s) and items from both the finished goods bill of materials and the container bill
of materials.
Include Finished Good BOMS Labor Info.

Select Yes to include any labor costs that are part of the finished goods bill of materials or
container bill of materials. If you select No, then labor costs from bills of materials (if any)
will not be printed.
32 Sage PFW
Setting up Scheduling
Introduction
The Scheduling Formula menu item will automatically schedule production orders based
on simple formulas that you set up using the Scheduling Formula option, which is
accessed from the Production ‐ File Maintenance folder. Setting up these scheduling
formulas is described in this section.
Note: If you do not intend to use the Production Scheduling option to schedule
Production
production orders at this time, then you do not need to set up scheduling
formulas.
However, if you decide later that you wish to use the Production Scheduling
option, you must define equations to determine the need to schedule certain items
for production.
If you have the Material Requirements Planning (MRP) application, you will want to use
that applicationʹs Production Scheduling option, which has built‐in algorithms to
schedule production based on customer orders and minimum inventory requirements,
and does not require you to enter equations to schedule production.
The Scheduling Formula (PNSHFORM) file contains a record of each formula used to
generate a production schedule record, which will contain all of the data necessary to
convert the scheduled batches into real production orders.
The scheduling formulas defined in this file each contain two equations. The first equation
(called the condition equation) is used to determine whether an item needs to be
scheduled for production. This equation consists of two expressions, which are compared
by a logical operator. If it is determined that an item should be scheduled for production,
the second equation (called the quantity to schedule equation) is used to determine how
many items should be produced.
Note: The term formula, in this option, identifies a pair of equations used to
schedule production orders, not a formula which contains raw materials, etc.

Scheduling Formula window

When you select Scheduling Formula from the Schedule Processing folder, the following
screen displays.
How to Complete the Scheduling Formula Window
Procedure
To complete the Scheduling Formula window, do the following:
Step Action
1 Select Scheduling Formula from the business desktop.

The Scheduling Formula window appears.
2 Complete the tabs in the Scheduling Formula window.
3 Select Save.
Description of Scheduling Formula Options
Formula Key
If you are setting up a new scheduling formula, enter a unique key to identify the record.
This key will be used in the Production Scheduling option to assign the formula that will
be used to calculate the need to schedule production.
34 Sage PFW
Description of Scheduling Formula Options
Description
The description of an existing scheduling formula that you inquired from the Formula
Key field will be displayed in this field.
If you are setting up a new scheduling formula, enter a brief description. Enter the most
descriptive part first, as some reports and listings will not have space to print the full
description in many reports, listings, and screens.
Expression 1
Enter the equation that you would like to use to determine whether a finished good (or
intermediate) should be scheduled for production. This expression may contain variables,
Production
arithmetic operators and constant values. Codes for variable quantities are listed in the
table on the right side of your screen. Symbols for the arithmetic operators are listed in the
Quantity and Arithmetic lists. Leave no spaces between variables and arithmetic
operators. Brackets [ ] and parentheses ( ) may be used to define calculations to be
performed within the equation.
Logic Operator
Enter the logic operator you would like to use to compare Expression 1 and Expression 2.
Symbols for the logic operators you may use are greater than >, less than <, equal to =, and
not equal to #. These symbols are listed in the Logical list.
Expression 2
Enter an equation for the quantity to which Expression 1 is being compared. This equation
may contain variables, arithmetic operators, and constant values.
Codes for the variables and symbols for the arithmetic operators are listed in the tables
displayed on the screen. Leave no spaces between variables and arithmetic operators.
Brackets [ ] and parentheses () may be used to define calculations to be performed within
the equation.
Formula
Enter an equation for the number of items that should be scheduled for production if the
conditions of the first equation are met.
This equation may contain variables, arithmetic operators, and constant values. Codes for
the variables and symbols for the arithmetic operators are listed in the Quantity and
Arithmetic lists. Leave no spaces between variables and arithmetic operators. Brackets [ ]
and parentheses ( ) may be used to define calculations to be performed within the
equation.

Setting up Responsibilities
Description
The Responsibility file allows you to define Responsibility Keys that you can use to keep
track of who is responsible for production orders. You can assign a Responsibility Key to
each user, workstation, group, or any other entity that is meaningful to your business
operations.
Responsibility window
When you select Responsibility from the File Maintenance folder, the following screen
displays.
How to Complete the Responsibility Window
Procedure
To complete the Responsibility window, do the following:
Step Action
1 Select Responsibility from the business desktop. The

Responsibility window appears.
2 Complete the tabs in the Responsibility window.
3 Select Save.
36 Sage PFW
Description of Responsibility Options
Description of Responsibility Options
Responsibility Key
You can use this field to create or edit a key that will be used to identify the person, group,
or workstation that is responsible for a batch. This key appears on many reports and can
be included on the batch ticket.
Description
This field allows you to enter or edit the description of the Responsibility Key. This
Production
description can contain up to 30 alphanumeric characters.

38 Sage PFW
Chapter 3:
Using Production
Introduction
The Batch Processing folder is where you will enter and maintain your current production
orders. This folder provides the menu items necessary for maintaining your orders. The
files accessed are Production Master (PNMAST) file, Production Finished Goods
(PNFINGD) file and Production Formula Line Item (PNITEM) file, which contain the
complete data for each batch in process, including formula ingredients, manufacturing
instructions, Q/C test requirements, and labor and overhead costs which were attached to
the master formula.
In this chapter
This chapter contains the following sections:
Chapter 3: Using
Production
Topic Page
Methods of Entering Production Orders 40
Printing Batch Tickets 54
Printing the Production Master Listing 57
Changing the Status of a Batch 59
Scheduling Production 71
Purging Schedule Records 85

Methods of Entering Production Orders
Introduction
Production orders may be created in either of two ways; manually, through the Batch
Entry option, and automatically, through the Production Scheduling option. The methods
are outlined as follows:
Method 1 - Manual Entry

Production orders may be entered manually using the Batch Entry menu item. Using this
method, you first specify the formula to be manufactured, enter a list of one or more
finished goods which the formula produces, size the batch accordingly, and enter
additional information such as the customer key and scheduled starting date. When you
process the record, a new production order is created. You can print a fully‐detailed batch
ticket as soon as you enter the data listed in this paragraph.
Method 2 - Automated Production Scheduling

Production orders may be automatically scheduled (with most data fields filled in) by
using the Scheduling option. This procedure is outlined as follows. See the chapter of this
manual entitled Scheduling Production for more details.
1. First you generate a schedule file, using the Generate Schedule menu item, which cal‐
culates the number of products that need to be manufactured, based on simple sched‐
uling formulas that you set up through Scheduling Formula File Maintenance. These
formulas consider current inventory and minimum stock levels, orders entered in the
Order Entry Pro application, and so forth.
2. Next, you edit the list of scheduled production orders (which are only proposed, at
this point), through Schedule Entry/Correction, to eliminate any orders that may not
be required or desired, and to possibly add schedule records for additional produc‐
tion orders, or adjust the quantity ordered for particular items.
3. Finally, the Create Batches from Schedule utility is provided to convert the scheduled
production orders to actual live production orders. A report will be generated detail‐
ing the new production orders that were created. The schedule file will remain intact
until you generate a new schedule by selecting Create A New Schedule rather than
Append The Existing Schedule in the Generate Schedule option.
Note: If several products are made from the same formula, they can be combined
into a single production order, saving you time and money!
If you have Material Requirements Planning (MRP), you should use the Production
Scheduling option in that application, exclusively. It will automatically generate a
production schedule based on customer orders and minimum inventory levels that you
have established, and for any in house intermediate formulas that will be required in the
scheduled top‐level formulas.
With MRP, all of your production scheduling can be automated. You will still need to use
the Create Batches From Schedule option in the Production application to convert MRP‐
scheduled orders to live production orders. This process allows you to have final
approval before the production schedule records can be used to generate batch tickets.
40 Sage PFW
Creating/Updating Production Orders
Creating/Updating Production Orders

You can create new orders using existing formulas and materials, make modifications to
how raw materials and formulas are used in both new and existing batches, adjust the size
of batches to meet customer demands or changing circumstances.
When you select Batch Entry from the Batch Processing folder, you will see the
Production Batch tab.
Chapter 3: Using
Production
Inquiring an Existing Production Order
You can inquire a previously entered batch by clicking the Find Record button. Select a
batch from the lookup window and all of the details pre‐loads into the appropriate tabs.
How to Enter Production Orders

When you enter information in the Batch Entry window, much of the information is filled
in with defaults, based on the formula key you select. You do need to add supplemental
information as this process continues.

Procedure
To enter a new production order, do the following:
Step Action
1 Select Batch Entry from the Batch Processing folder.
2 If you are entering a new batch, select the New Record button.
The following screen displays:
Batch Number
The batch number displayed in this field is taken from Production -
Application Setup. You can accept the displayed number, or you
can enter your own number.
If you choose to enter your own number, and that number has
already been used, the numbering sequence is advanced to the
next available number.
Formula Key
Enter a formula key, or choose one from the lookup window, from
which this batch will be made.
Description
The description field is disabled, thus you may only view the
description of the formula selected in the above field.
Fill From Inventory
If you enter a formula key which also has a raw material which uses
the same key, and is identified as an in-house intermediate, you
can choose to use the master formula or you can use the raw
material intermediate.
If you leave this checkbox unselected, the raw materials from the
master formula is used. If you select this checkbox, the raw material
intermediate which has the identical key as the master formula is
used.
Default Location
Select a default location from which raw material stock will be
drawn. Select Finish to begin adding the batch.
3 You are returned to the Batch Entry screen so that you can con-
tinue entering the production order.
42 Sage PFW
Batch Entry Fields - Batch Tab
Batch Entry Fields - Batch Tab
Batch Number and Formula Key

The Batch Number and Formula Key fields are not accessible on this tab. They will
display the data that was entered on the Create New Batch screen.
Note: The Formula key has a lookup button that allows you to view any Univer‐
sal Notes and Attachments for all formula keys or only the Finished Good Keys
that match the formula, depending upon how you have setup the Edit Report tab
in Application Setup. The Formula Key cannot be changed once assigned to a
batch ‐ not even through the lookup button.
Some of the data required on this screen will be provided by default for new orders, such
as the date the order was created and the status (always New for new orders).
Description 1-2
One or two lines of the description from the selected formula will be displayed here.
Chapter 3: Using
These lines will automatically be displayed if the selected formula has a description, but
Production
their content can be altered here if necessary, and you can select whether to have one, two
or none of these lines printed on the batch ticket, in Batch Ticket Layout file maintenance.
This allows you to enter a special product name, perhaps a house brand that you
manufacture exclusively for one of your customers, using one of your standard formulas,
which you modify slightly in this option, to meet the customerʹs requirements.
Customer Key
Enter the key of the customer for which this batch is being prepared. This field is for
informational purposes only, but you can select to have it printed on the batch ticket, in
Batch Ticket Layout file maintenance.
Responsibility
Enter your user or workstation identification (ID) key to indicate who is responsible for
creating this production order. User or workstation IDʹs are set up through Responsibility
file maintenance.
Production Order Date

The date that this production order was created will be displayed here, automatically.
Scheduled Start Date

Enter the start date that this production order is to be processed. If it is left blank, the date
defaults as soon as a transaction occurs against any line item in the batch. This would
include committing or requisitioning one or more finished goods or formula line items.

You can leave this field blank to default the current processing date, or you can enter a
future date on which you would like the batch to start processing. Once you enter a
scheduled start date, this date is not change if you start processing the batch before the
scheduled start date.
Scheduled Completion Date

The Completion Date field will automatically be filled in when the batch is closed. You
can enter a scheduled completion date, if you wish, which will be printed on the batch
ticket.
Actual Start Date

When you begin processing this batch, you can enter the date on which processing
actually began.
Actual Completion Date

When you have finished processing this batch, you can enter the date on which processing
actually completed. Use the Lookup button next to the field to make your selection.
Edit Report Status

This field displays when either of the “Require Edit Report before...” options, found in
Application Setup, are set to either Required or Warning (refer to “Edit Report Tab” on
page 19 for additional information).
If an Edit Report is required or set to warning
If this field displays ‘Passed’, the status on the Finished Goods or Formulas tabs can be set
to Finished or Requisitioned because an error‐free edit report was run.
If this field displays ‘Not Valid’ or ‘Failed’, the status on the Finished Goods or Formula
tabs can not be set to Finished or Requisitioned until an error‐free edit report is run.
Production Status
The current production status of this order is displayed here. This field cannot be accessed
on this screen. If this is a new batch, the status will default to New. If this is an existing
batch, this field will reflect the highest status of any line item in the production order.
Order Weight/order Volume

These fields show the total weight and volume of all finished goods and intermediate raw
materials which will be created by this batch.
These fields are adjusted by added or removing line items from the Finished Goods tab.
Batch Weight/batch Volume

These fields show the total weight and volume of the batch, regardless of the finished
goods being created.
44 Sage PFW
Miscellaneous Tab
These fields are adjusted by added or removing line items from the Formula tab and
resizing the formula.
Special Features
Printing a batch ticket
You can print batch tickets from the Batch Entry option by clicking the Print Batch Ticket
button. This option can be used to print a production order that you have just created.
Printing a Batch Edit Report
You can print an edit report for the current batch from within Batch Entry. When the
Batch Edit Report is run from within Batch Entry the report looks only at the current
saved batch data in the Production. You can not run the Batch Edit Report without first
saving the batch. Additionally, when you run this report, the currently loaded batch is
released from the Batch Entry screen. If you want to make changes to the batch found on
the edit report, you need to re‐inquire the batch.
When you select the Print Batch Edit Report button, the currently displayed batch is
analyzed by the edit report and an edit report prints only if the Routing tab is set to
Chapter 3: Using
printer. An Edit Report Status is assigned and the Batch Edit Report can be printed as
Production
often as desired.
Miscellaneous Tab
Order Printed
If this is a new production order, this field will default to unselected. Select this checkbox
if you have already printed this ticket.
Density Override
Enter the density for this batch if it is going to be different than calculated. The density is
correctly calculated using the information in the Item Master (INMAST) file based on the
total weight or volume of all the ingredients. However, a reaction may occur in some
formulas that cannot be calculated or accounted for. If the finished batch density is going
to be different than calculated, then you can override it by entering a density that you
know to be correct.
Order Time
This field shows the time at which this batch ticket was created. You can manually change
this field, if necessary.
Scheduled Start Time

Enter the start time that this production order is to be processed. If it is left blank, the time
is calculated as soon as a transaction occurs against any line item in the batch. This would
include committing or requisitioning one or more finished goods or formula line items.

Scheduled Completion Time

You can enter a scheduled completion time, if you wish, which will be printed on the
batch ticket.
Actual Start Time

When you begin processing this batch, you can enter the time at which processing
actually began.
Actual Completion Time

When you have finished processing this batch, you can enter the time at which processing
actually completed.
Batch Type
Select the type of processing which best describes this batch. This field is for your
informational use only. Make your selection using the drop‐down box next to the field.
Batch Type Definition

Mix This batch is the normal process - a mix-
ture of raw materials.
Fill From Intermedi- This batch is scheduled to be filled from
ate intermediate stock which was previ-
ously produced.
Fill From Mixture This indicates that this batch is to be
filled from a batch already in process.
Assembly This indicates that this batch needs to
be physically put together, perhaps
from finished goods already in stock.
Process Cell
Select the process cell from the lookup, which is assigned to process this batch.
Estimate Run Time

Enter the amount of time, which this Machine Center will take to process this batch.
Note 1 - 4
You may enter up to four lines of notes or comments of up to 40 characters per line to add
special instructions to this production order. Notes can optionally be printed on your
batch tickets, by selecting that option in the Batch Ticket Layout option.
Costs Tab
46 Sage PFW
Finished Goods tab
All of the information required on the Costs tab is copied from the master formula and
entered for you. Unless you need to modify the setup cost data, you donʹt have to do
anything on this tab.
Setup Costs
Similar to Fixed Costs, Setup Costs allow you to take into account additional charges
incurred when starting this production order. You can specify the amount of time
required to set up the batch which might include gathering the raw materials and
containers. These costs could vary from batch to batch, and could reflect variable criteria
such as the number of employees assigned to prepare the batch. When the batch is closed,
these costs are then calculated into the final cost of the finished good or intermediate
material.
Finished Goods tab

This is where you can enter the finished goods to be produced from this batch, and adjust
the size of the batch according to the finished goods ordered, or other criteria of your
choice, by clicking the Size Batch button.
Chapter 3: Using
The Finished Goods tab provides you with access to two different lookups. One lookup
Production
displays intermediate items. While the second displays either all finished goods formula
keys or only the finished good keys that match the batch formula, depending upon how
you have setup the Edit Report tab in Application Setup.
If you setup the Formula differs from Batch Formula option as an Error, the lookup found in
Batch Entry on the Finished Goods tab is restricted to show only the Formula keys
matching the Batch Formula. If this option is setup as a Warning or None, the lookup
displays all item keys.
Line Items Sheet

Status
The status of the individual line items is displayed in this column. For new batches, select
New.
If you change the line status to Finished or Requisitioned and the Edit Report Status on
the Batch tab is not ‘Passed’ a message displays based on how you setup the Application
Setup ‐ Edit Report Tab. If you setup the ‘Require Edit Report Before...’ option as:
• Required ‐ An error‐free Batch Edit Report must be run prior to Finishing or Req‐
uisitioning a batch. All changes are being saved except the new Finishes and/or
Requisitions.
• Warning ‐ An error‐free Batch Edit Report has not been run for this batch. You
can click OK to continue the process or Cancel to stop the process.
• None ‐ No message is received and the batch is finished or requisitioned.
Item Key
You can open a lookup window listing all the finished goods associated with the formula
you chose on the header screen. Select the key of the finished good that you would like to
produce from this batch.

Location
This key represents the inventory location where this finished good will be carried when
the batch is completed. This field defaults to the first finished good location, when you
select a finished good. If you have more than one finished good location, you can use the
lookup window which displays a list of all the inventory locations that you have
previously defined.
Qty Ordered
Enter a value to indicate the number of finished goods you would like to produce, based
on the unit of measure displayed for the finished good. You may press the Unit of
Measure button to change the unit of measure for this line item, before you enter the
quantity. Typically, finished goods will be measured as Each, while intermediates and
bulk products will be specified in terms of weight or volume.
Qty Produced
If the number of finished goods actually produced is different than the number placed on‐
order, enter that number here. The value is copied from the Quantity Ordered field to the
Quantity Produced field when the batch ticket is closed, if the quantity produced field is
left blank. If you enter a value in this field, then it will be used instead of the value in the
Quantity Ordered field, and record the correct number of finished goods produced when
the batch is closed.
Unit
The unit of measure displayed in this column will depend on whether the item key for
this line is a finished good or raw material (i.e., an intermediate or bulk product). If you
have selected a finished good, then the unit shown will be each, or an alternate unit of
measure that you have previously defined and attached to this finished good in the
Inventory Pro Item Master file maintenance.
Note: If the item key is a raw material (i.e., an intermediate or bulk product), the
unit shown will be the one specified in Inventory Pro, which will be units of either
weight or volume. You can change the unit of measure by clicking the Unit of
Measure button to toggle between weight or volume for a raw material, or
between each and alternate units of measure that you have defined and attached
to a finished good in Inventory Pro.
Customer
If you are producing this finished good for a specific customer, enter that customerʹs key
here. You can select a customer key from the lookup window, which will display all the
customer keys you have defined through Inventory Pro or Order Entry Pro file
maintenance. This field is filled in when creating a production schedule record based on a
customer order posted in the Order Entry Pro application.
You may enter several lines of the same or different finished goods which result from the
selected formula, each with a different customer key, when appropriate. This allows you
to combine two or more different customerʹs orders into a larger, more efficient batch.
Comment
You may enter a short comment about the production of each finished good. This
comment may optionally be printed on the batch ticket.
48 Sage PFW
Finished Goods tab
Lot/Bin/SSCC Sheet
This sheet allows you to assign lot numbers, bin numbers, and/or SSCC numbers prior to
closing the batch. In addition, you can specify a quarantine date, which will prevent this
lot‐tracked item from being used or sold until after that date, and an expiration date
which will indicate when this lot‐tracked item should no longer be used or sold.
Lot, Bin, SSCC
To assign a lot number, bin number, or SSCC, move the cursor to the desired field. Type
the finished good lot number that you wish to assign to this batch. You may enter up to 20
characters. Press <Tab> to accept the new lot/bin/SSCC number.
Quarantine Date
After you have entered a lot number, bin number, or SSCC, press <Tab> to move the
cursor to the Quarantine Date field. If you would like to prevent a lot from being sold or
used before a specific date, you may enter that date here. If you do not need to use a
quarantine date, you may leave this field blank and press <Tab> to move the cursor to the
next field.
Expiration Date
Enter the date after which this batch/lot may (optionally) be prevented from being sold in
the Order Entry Pro application. If this lot does not have limited shelf life, you may select
the Line Items sheet to enter additional lot information for other finished goods on the
Chapter 3: Using
Production
order, or you may go to one of the other tabs to further adjust the formula.
Note: Individual finished goods may be added to inventory on‐hand quantities
when they are finished, without waiting for the batch to close. This is done by set‐
ting the finished good status to F (for Finished). This allows you to ship finished
goods which have been completed before all of the finished goods on a batch have
been filled. Otherwise you might be processing an over‐sold quantity until the
batch was closed.
The cost for this finished good will be based on the batch costs accumulated up to the
point the finished good status is changed to F (for Finished). When the batch is completed,
if the finished good cost has changed, the Last Cost and Average Cost fields in the Item
Location (INLOC) file and Inventory Pro Transaction History (INTXDH) file will be
adjusted to reflect the accurate costs. If you have flagged any of the finished goods on this
order to require lot numbers (in Inventory Pro), you should assign a lot number to the
batch before you change the status of any items to Finished.

Special Features
Sizing a Batch Button
Batches can be sized by a variety of different methods. This allows you to match the batch
size to accommodate any requirement, from customer orders to refilling on‐hand stock.
When you click the Size Batch button, the Size Batch Wizard will display the following
methods for sizing the batch.
Field Descriptions
Weight*
This option allows you to size the batch to achieve a specific weight.
Volume*
This option allows you to size the batch to achieve a specific volume
Finished Goods Ordered*
You can adjust the size of the batch based on the total number of finished goods to be
produced and the capacity of the container attached to that finished good.
% of Formula in Process*
You can adjust the size of the batch based on a percentage of the master formula. This is a
handy way of halving, doubling, or quadrupling your master formula without having to
create a new master formula.
Premix Quantity*
This option allows you to size the batch based on the requirements at a specific point in
the batch. For example, suppose you had a grinding drum which could hold 100 pounds
of material. You could size the entire formula so that the ingredients that were to be
ground could be 100 pounds or less. The entire formula is then adjusted to maintain the
original ratio of materials.
To set a premix size, enter ^W for weight ^V for volume, on a Text mode line. Click the
Batch Size button, and the Size Batch Wizard will appear. Select Premix Quantity. The
Size Formula By Premix pop‐up window will appear. Enter the desired weight or volume,
loss factor, and loss constant to be applied to this sizing. Your formula will now be sized
accordingly, with the materials before the ^W or ^V sized to the premix value.
* The batch‐sizing methods with an asterisk allow you to adjust the loss factor and loss
constant.
50 Sage PFW
Finished Goods tab
Available Materials
When you select this option, the on‐hand inventory quantities of all the raw materials in
the batch are checked and determine which material is the limiting factor. The rest of the
batch will be sized to use all of this limiting material.
Availability of One Material
When you select this option, a pop‐up window displays which will allow you to select a
single material and location by which the entire batch will be scaled. This scaling will be
based on the maximum quantity available on‐hand. Note that this may make some
materials appear on the Critical Material report.
Quantity of One Material
When you select this option and click the Next button, a list displays which allows you to
specify a single material, location, and a quantity by which the entire batch will be scaled.
Note that this may make some materials appear on the Critical Material report. The item
key/location key combination must already exist in the formula in process.
All batch sizing methods allow you to include or exclude line item loss when the batch is
sized. All batch sizing methods allow you to scale the By Products produced by the batch
as well.
Adjusting Finished Goods Bill of Materials Quantities Button
Chapter 3: Using
Production
Finished goods bills of materials may be adjusted to reflect actual usage. Once you have
entered one or more finished goods on this screen, you can highlight the finished good
whose bill of materials you would like to adjust and click the Bill of Materials button. A
Bill of Material pop‐up window will appear, similar to the following illustration. You can
only adjust the Quantity Required, Quantity Used, and Overhead for each bill of material
item, including the container which has been specified for the finished good, and bill of
materials items which were attached to the container.
The value that you enter into the Qty Used column for a container will be the actual
number of containers relieved from inventory, regardless of the number of finished goods
produced. If you leave the Qty Used column blank, the number of containers specified for
the finished good or container bill of materials will be relieved.
If your finished goods use a variety of containers, depending on what you may have in
stock at the time, you can enter all of the containers as bill‐of‐material items through the
Inventory Item Entry, Bill of Materials tab. Be sure to set their quantity required to zero.
Then, when you create a batch ticket and enter the finished goods, you can access the Bill‐
of‐Materials pop‐up window and enter the quantity required for only those containers
which you plan to use for that order.

Formula Tab
The Formula tab is similar to the Formula Line Item Maintenance Screen, which was
copied from the master formula you entered on the header screen, along with batch
weight, volume, and cost data. Here you can view or edit the formula ingredients and
manufacturing instructions, and modify them just for this batch, if necessary. This screen
provides several utility commands, for switching to alternate unit(s) of measure, viewing
the complete text of boilerplates or literal manufacturing instructions, sizing the batch, or
changing the status of all the ingredient line items when you commit or requisition
materials for the batch.
Additional information is provided below.
Field Descriptions
Status
If you change the line status to Finished or Requisitioned and the Edit Report Status on
the Batch tab is not ‘Passed’ a message displays based on how you setup the Application
Setup ‐ Edit Report Tab. If you setup the ‘Require Edit Report Before...’ option as:
• Required ‐ An error‐free Batch Edit Report must be run prior to Finishing or Req‐
uisitioning a batch. All changes are being saved except the new Finishes and/or
Requisitions.
• Warning ‐ An error‐free Batch Edit Report has not been run for this batch. You
can click OK to continue the process or Cancel to stop the process.
• None ‐ No message is received and the batch is finished or requisitioned.
Note: On this tab, the warning messages are received for Inventory and Labor
types only.
Qty Required
The weight or volume of the raw material line item required to complete this batch is
displayed here. If you use any of the automatic sizing options, this column will adjust
itself based on your selections. This is the quantity of material, which will be relieved from
on‐hand inventory, unless you enter a value in the Qty Used field.
Qty Used
Enter the quantity of this material actually used in the batch, if it is different from the Qty
Required field. If this field is left blank, the amount in Qty Required will automatically be
entered in this field when the item is requisitioned (or the order is closed). If you enter a
non‐zero value in this field, this will be the actual quantity of material relieved from on‐
hand inventory, regardless of the value in the Qty Required field.
Special Features
Toggling the Unit of Measure Button
If you have defined alternate units of measure and attached them to you raw materials,
you can toggle between weight, volume, and any alternate units of measure attached to
that particular line item, by clicking the Unit of Measure button.
52 Sage PFW
By-Products Tab
Identifying Material Shortages
Another handy feature on is the View Critical Materials button. Press this key to open a
pop‐up window which indicates whether any material shortages will result from
requisitioning the quantity of materials specified on this screen. If any shortages are
found, the screen will display the item key, location, quantity on hand, quantity required
for the current order, quantity short for the current order, and in addition, the quantity
required and quantity short for all committed orders.
The following illustration shows the Insufficient Quantities pop‐up window. Note that in
this case the current order cannot be requisitioned, since there is insufficient quantity on
hand for the current order quantity required. Other orders have also been committed, so
you are notified that a shortage will occur if any other currently committed orders are
requisitioned as well.
Chapter 3: Using
Production
By-Products Tab
If the batch you are processing creates additional materials as a result of the processes it
undergoes, then you can enter the quantity created by this batch for those items on this
tab. When the batch ticket is closed, these items will be placed on‐hand. These items must
already exist in the Inventory Pro database; Production does not backwrite by‐products.
Q/C Results Tab

This tab allows you to view and edit your Production quality control (Q/C) test results.
The test descriptions, target values and upper and lower limits for test results are
established in the Formulas application, and transferred automatically to each production
order which uses that formula.
This is where you will enter the test results, which will be associated with your finished
goods. This is a powerful option, allowing you to add or delete quality control tests
specified for the master formula on which this batch is based. For a description of the data
fields, see your Formulas Userʹs Guide.

Printing Batch Tickets
Description
The Print Batch Ticket option allows you to print your production orders to create batch
tickets, which can be used as to document and authorize the requisition of raw materials,
enter Q/C test results and track the status of production orders. If you use the Batch Ticket
Layout and Batch Ticket Boilerplate options, you can create a custom batch ticket to best
suit your companyʹs needs.
Note: You can also print batch tickets from the Batch Entry option by clicking the
Print Batch Ticket button. This is a handy option which can be used to print a pro‐
duction order that you have just created.
How to Print Batch Tickets

You can selectively print batch tickets from within Batch Entry or by selecting the Print
Batch Tickets menu item. If you choose to print the batch ticket using the Print Batch
Ticket menu item, do the following.
Procedure
Use the following procedure to print batch tickets:
Step Action
1 Select Print Batch Tickets from the business desktop.
2 Select an existing saved parameter to edit or pro-

cess; or select New to create a new parameter.
3 Complete the tabs on the Parameters tab.
4 Save the parameters if desired, then select Process.

Sort Keys
You may select from four different sort‐key combinations to sequence or limit the range of
batch tickets to print. The key listed first is the primary key, in each case. The Order ‐By
submenu lists the following sort keys for your selection:
• Batch Number
• Formula Key / Batch Number
• Responsibility Key / Batch Number
• Customer Key / Batch Number
54 Sage PFW
How to Print Batch Tickets
Parameter Maintenance
The Parameter Maintenance screen for printing batch tickets sequenced by batch number
will appear similar to the following illustration.
Chapter 3: Using
Production
Range Fields
The names of the keys selected from the Order By submenu complete the titles of these
fields. They define the keys by which records will be sequenced from the source files.
Production Status
Enter a production order status key, if you wish to limit the batch tickets you are printing
to a single status, or just leave this field blank, which will print the range of batch tickets
you defined in the range field(s), above, regardless of their status.
Production Order Printed
If you Select No, this field allows you to restrict the printing to only those orders which
have not been printed previously, among the range of batch numbers, etc., that you
defined in the range field(s). If you Select Yes, only those orders which have previously
been printed will be printed again. This field defaults to All, which will print all batch
tickets.
Crystal Reports
This field defaults to the pre‐defined batch ticket file name. You can use the default or
create a new Crystal Report. The report must be located in the Platinum\PFWRes\Master
directory or it will not print properly.
Include Boilerplates
If you check this field, boilerplate text which has been entered in the master formula as
line items will be printed on the batch tickets.
Include Literal Text
If you check this field, literal text manufacturing instructions which were entered in the
master formula as line items will be printed on the batch tickets.
Include Raw Material Lot Numbers
If you check this field blank, lot numbers will print for raw materials which are lot tracked
and have already had lot numbers assigned to the batch.

Include Finished Good Lot Numbers
If you check this field blank, lot numbers will print for finished goods which are lot
tracked and have already had lot numbers assigned to the batch.
Sample Batch Ticket

To view a sample report, click the following button:
56 Sage PFW
How to Print a Production Master Listing
Printing the Production Master Listing
Description
This option allows you to view or print one or more records from your Production Master
(PNMAST) file. This will allow you to review your open production orders, or work‐in‐
process.
Procedure
Use the following procedure to print a Production Master Listing:
Step Action
1 Select Production Master Listing from the business desk-
Chapter 3: Using
top.
Production
3 Complete the tab on the Parameters tab.

Sort Keys
The Production Master Listing may be sequenced by the batch number. This choice
appears on the Sequence‐By list when you select this option from the Production menu.

Select one or more parameters by which the Production Master Listing will be restricted
and sorted.
Range Fields
The names of the keys selected from the Sequence By submenu complete the titles of these
fields. They define the keys by which records will be sequenced from the source files.
Include Description
Select Yes to include the formula description in the listing.
Select No if you do not want the description to appear on the listing.
Include Notes
Select Yes to include the first line of notes attached to this formula.
Select No if you do not want the notes to appear on the listing.
Sample Production Master Listing

Your Production Master Report may appear different due to the capability to customize
the Production Master Report. For example, the following Production Master Report was
printed with the Include Description field set to No, so the formula descriptions are not
included. You can include just the information you need, so that your reports and listings
are concise and easy to read.
58 Sage PFW
Changing the Status of a Batch
Description
The status of a batch is determined by the highest status of any of its finished goods or
formula line‐items (from New to Finished). When a production order is first created (by
either method described earlier in this chapter), each new record in the Production
Master, Production Finished Goods, and Production Formula Line Item files are assigned
a status of New, indicating that this is a new production order and no operations have
been performed on it.
You may wish to print batch tickets with a status of New or Committed, for production
planning, but production actually begins when a batch ticket has a status of
Requisitioned, which means that at least one material line item has been transferred from
inventory to production, and that material can be physically withdrawn from inventory.
Normally, you will use one of the Batch Processing folder (Activate Batch, Cancel Batch,
Hold Batch, etc.) to change the overall status of a batch, from New to Committed (perhaps
when the customerʹs purchase order is received), from Committed to Requisitioned, and
Chapter 3: Using
then Finished and/or Done (partially or fully closed). However, to provide the greatest
Production
flexibility for your production management, you may assign statuses to individual line
items and finished goods, when necessary. These options are explained in the following
section.
Finished Goods Status

A production finished goods record will usually have a status of New, Committed,
Requisitioned or Finished. Only finished goods with a status of New or Committed can be
changed to Hold or X (canceled). Assigning a status of X (canceled) to a finished good
with a Committed status will cause any bill‐of‐materials items to be uncommitted in
Inventory.
Once a finished good has a status of Requisitioned or Finished; it cannot be canceled.
Finished goods with a status of Finished or X (canceled) may not be changed to any other
status.
Material Line Item Status

Production formula line‐item records will normally have a status of New, Committed,
Requisitioned, or Finished. Only line items with a status of New or Committed can be
changed to Hold or X (canceled). Assigning a status of X (canceled) to a Committed line
item will cause its quantity required to be uncommitted in Inventory, when you process
the record.
Once a line item status has been changed to Requisitioned, and the record processed, the
order cannot be canceled. Once a line‐item has been canceled, and the record processed, it
may not be changed back to any other status.

Placing Production Orders on Hold

A temporary status of Hold can be applied to production orders which have a status of
New, Committed, or Requisitioned. Use the Hold Batch option to place a production
order on Hold and prevent any further operations on the order until it has been removed
from Hold. Orders on Hold can be viewed from the Batch Entry option, but changes to the
batch may not be made. When an order that was on Hold is activated, the status will
revert to what it was before the order was placed on Hold.
Activating Production Orders

Once a batch has been placed on Hold, then the status can only be changed to Active
through the use of the Activate Batch option.
Committing Production Orders

When you are ready to commit inventory for a production order (production orders may
be created well in advance of manufacture for planning purposes), you can use the
Commit Batch option to assign a status of Committed.
Even after a production order is committed, it may still be canceled providing that none of
the production formula line items or production finished goods has been requisitioned.
When a batch is canceled any committed inventory items prior to canceling the order is
uncommitted.
When a production order is committed, all of the production formula line items and
production finished goods that have a status of New will be changed to Committed, and
inventory committed‐to‐production figures will be increased for each raw material in the
formula as well as for inventory items in the finished goodsʹ bills‐of‐materials and in the
containerʹs bills‐of‐materials.
In the case of production finished goods, the status of Committed means committed to
being manufactured (also items in their bills‐of‐materials are committed to production).
Inventory on‐hand is not adjusted for any items when a production order is committed,
nor are any files other than the Production Formula Line Item (PNITEM) file affected by
committing labor. Overhead does not effect any files when records are committed.
Once even a single line item in the production order is committed, you may not insert or
remove line items or change item keys in the production line items that would affect the
order or line number of any existing item. You may, however, add new line items (in
existing blank lines or at the end) prior to any of the orderʹs finished goods being assigned
a status of Finished.
Note: Materials that are not lot‐tracked and assigned during the commit process
may be committed to production whether or not there is sufficient quantity on
hand to satisfy the requirements. This is permitted because committing materials
to production does not change the quantity on‐hand.
Also, committing inventory does not reserve it for a particular batch. Although a quantity
is listed in the Committed To Production field, the items are still “on the shelf,” and could
be requisitioned for another order.
60 Sage PFW
Assigning Lot Numbers for Raw Material Usage
Assigning Lot Numbers for Raw Material Usage

If you have answered Yes to the Assign Lots During Commit field in the Production
Application Setup menu item, a pop‐up window will appear. This window displays all of
the available lots for the item being committed, their purchase date, bin number, SSCC, lot
status, lot strength, and quantity available. You can either automatically assign the
required quantities, or you can manually enter quantities until the Total Quantity
Assigned field equals the Total Quantity Required field. Lot‐tracked items are relieved
starting with the first lot in the list and continue down the list until sufficient quantity has
been allocated. You can select, in the Lot Tracking Configuration option, to have lots
assigned based on their expiration date, purchase date or quarantine date.
If you selected No in the Assign Lots During Commit option, the pop‐up window will not
appear until you requisition a lot‐tracked item, or use the Close Batch option.
If you do not have enough quantity of a lot‐tracked item to assign to a batch, a message
displays.
No lots qualified for selection are available for item _________.

Batch will not be processed.
Note: If you use lot‐strength factors, you must have the Assign Lots During Com‐
Chapter 3: Using
Production
mit field set to Yes. The Adjusted field in the pop‐up window will show the actual
quantity of the lot‐tracked item which will be added to the Commit To Production
field in the Item Location (INLOC) file, based on the lot strength.
If a batch has a status of Committed, and you size the batch, the Committed To
Production field in inventory will be adjusted automatically. A batch may be increased in
size when its status is either New or Committed, but may not be sized after any formula
line item has a status of Requisitioned.
If you have chosen to assign material lots when items are committed, and you
subsequently increase the size the batch, the Lot Selection Pop‐Up window will appear,
and prompt you to assign the additional quantities of lot‐tracked items.
If you decrease the size of a batch, you cannot reduce the lot quantities that have been
assigned. If the batch status is committed and lots have been committed, uncommit the
batch and then resize it.
Uncommiting Production Orders

The Un‐Commit Batch option allows you to un‐commit one or an entire range of
production orders. Only committed batches (or line items) may be un‐committed. If you
try to un‐commit a batch in which any formula line item or finished good is beyond the
Committed status (e.g., Requisitioned), then the order will not be un‐committed.
Requisitioning Production Orders

The status of production formula line items and production finished goods can be
changed from New or Committed to Requisitioned, individually if necessary, through the
Batch Entry option. When any one of these itemʹs status is changed to Requisitioned, the
overall status of the order is also changed to Requisitioned.

However, in most cases you will use the Requisition Batch option, which will change the
status of all the material and labor line items, and all of the finished goods on the order,
and the overall status of the batch from New or Committed (or partially Requisitioned) to
Requisitioned.
When you run Requisition Batch for batches in without an error‐free edit report, a
message displays based on how you setup the Application Setup ‐ Edit Report Tab. The
following message displays if you selected:
• Required ‐ There are no qualified batches in the specified range.
• Warning ‐ An error free Batch Edit Report has not been printed for one or more
batches. Click ‘OK’ to continue the process or ‘Cancel’ to stop the process.
• None ‐ No message is received, the batch can be requisitioned.
If any of the material line items being requisitioned were identified in inventory as
requiring lot tracking, and you did not select to assign lots during commitment, then the
pop‐up lot‐assignment window will appear, similar to the illustration, above. You can
assign the lots manually, or you can automatically assign lot number(s) to satisfy the
quantity required. You can select, in the Lot Tracking Configuration option, to assign lots
based on their expiration date, purchase date or quarantine date.
Note: Items may not be un‐requisitioned. Once items are requisitioned, they are
added to a batch, and cannot be returned to inventory.
Automatic Posting of Production Transactions

As material line items (not including labor or overhead) are requisitioned, they are
removed from both the Committed (for items which were previously committed) and On‐
hand fields in the Inventory Pro Item Location (INLOC) file.
Requisitions are posted in inventory as adjustment transactions, which credit the
inventory control account associated with the itemʹs class, and debit the account number
associated with Production adjustment transactions in the Inventory Pro Transaction
Subtype Description (INTXTYP) file. You can define transaction subtypes to suite your
business in the Inventory Pro System Defaults Transaction Sub‐Type Interface file
maintenance menu item.
For further information, see your Inventory Pro Userʹs Guide under Posting to the
General Ledger.
WARNING: Bill‐of‐materials items associated with containers or finished goods on
a production order are NOT transferred into a separate production file. So you
should NEVER modify a bill‐of‐materials (in Inventory Pro) for a finished good or
container that is currently part of an open production order.
The Production application operates on the assumption that the bill‐of‐materials for each
item in production will remain unchanged through the production cycle. Changing a bill‐
of‐materials could cause accounts to be thrown out of balance if different items or
quantities are present in the bill‐of‐materials at various points in the production cycle.
However, you may adjust the BOM quantities in Production, through the Batch Entry
option.
62 Sage PFW
Canceling Production Orders
Canceling Production Orders

The Cancel Batch option allows you to cancel one or an entire range of production orders.
If a batch is committed, uncommit it first. If you try to cancel a production order in which
any formula line item or finished good is beyond the Committed stage (e.g.,
Requisitioned), then that production order is not cancelled.
The reason orders may not be canceled after any inventory item has been requisitioned is
because it is assumed that materials are physically added to the batch when requisitioned,
and cannot be returned to inventory. Also, costs and lot numbers are determined (and are
no longer adjustable) at that time.
For example, if a customer cancels his order after the batch has been requisitioned, the
batch would typically have to be completed and the finished goods held in stock, allowing
the production order to be closed normally, since it cannot be canceled. In this example,
the Customer field should be changed to Stock before the order is closed.
Chapter 3: Using
Production

Closing Production Orders
Description
A production order can be closed as soon as you have entered a master formula key and
defined the finished goods to be produced. All of the steps between the status of New and
Finished are filled in.

Before closing a batch, you may have to print a Batch Edit Report. The Batch Edit Report
allows you to validate your entries made in Batch Entry before closing. Once a batch is
closed, it is extremely difficult to make adjustments to correct errors. This edit report gives
you the flexibility to consider errors and warnings to determine which batches are ready
to close and which batches need to be fixed.
You can make the Batch Edit Report a required or optional step or just a warning. In
Application Setup, on the Edit Report tab, there are two options Require Edit Report
before Batch Close and Require Edit Report Before Requisition or Finish that allows
you to determine this. When these options are set to either Required, an error‐free Batch
Edit Report must be run. The report must be error‐free before you can close a batch.
If you set these to Warning, you are notified when an error‐free edit report has not been
run, prior to Closing/Requisitions/Finishing a batch.
If you set these to options None, an edit report in not necessary.
The Batch Edit Report includes three types of statuses; E (Error), W (Warning), and P
(Requisition or Finished item with potential errors or warnings).
The *E flag alerts you to problems that must be fixed prior to closing a batch. The *W flag
indicates that there are situations that you may want to changes prior to closing the batch,
but fixing these conditions is optional.The ʹ*Pʹ flag indicates that the reported item has a
warning or error associated with it, but due to the status of the item (Requisitioned or
Finished), the Edit Report cannot generate an error if an error is the actual case. For
example, in Application Setup, the Batch Edit Report is ʹRequiredʹ and the ʹFormula Verify
Loss Constant per Batch Weightʹ option is set to ʹError.ʹ Before running the Requisition
Batch menu item, the ʹBatch Statusʹ in Batch Entry was Committed and the ʹEdit Report
Statusʹ was ʹFailed.ʹ When the Edit Report is run, the following error displays on the
report: *E‐Formula Loss Constant exceeds max. percentage of Batch Weight. Loss Const:
90.00 Batch Wt: 100.00 Max Pct: 50.00.
If you then run the Requisition Batch menu option, the ʹBatch Statusʹ in Batch Entry was
changed from ʹCommittedʹ to ʹRequisitionʹ and the Edit Report Status changed from
ʹFailedʹ to ʹPassedʹ. When the Edit Report is run again, the same message above displayed
but instead of *E, it displayed *P. Status *P lets you know that the batch is ʹpartiallyʹ
closed.
64 Sage PFW
Procedure
Use the following procedure to generate a Batch Edit Report:
Step Action
1 Select Batch Edit Report from the business desktop or

from Batch Entry.
3 Complete the parameter tab.

Batch Edit Report Window

When you select Batch Edit Report from the business desktop, the following displays:
Chapter 3: Using
Production
Sort Keys
You can choose to sequence the report by batch number. This is the only order‐by.
Parameter Fields
Range Fields
Define the range of batch numbers and/or formula keys that you wish to include in the
report. Use the Lookup button next to the field to make your selection.
Batch Status
You can select the statuses that you want to use to restrict the report. The statuses include;
All, New, Committed, Requisitioned, and Finished.

Report Contents
The Batch Edit Report lists the error or warnings for the current batches. To view a sample
report, click the following button:
Closing Batches
Based on how you setup the Application Setup ‐ Edit Report Tab, the Batch Edit Report
may be required. When you run Close Batch for batches in without an error‐free edit
report, a message displays based on how you setup the Application Setup ‐ Edit Report
Tab. The following message displays if you selected:
• Required ‐ There are no qualified batches in the specified range.
• Warning ‐ An error free Batch Edit Report has not been printed for one or more
batches. Click ‘OK’ to continue the process or ‘Cancel’ to stop the process.
Note: If you select Cancel, processing for all batches is cancelled.
• None ‐ No message is received, the batch can be closed.
All transactions will be completed and the data will be transferred to the Production
history files as outlined below.
When you select Close Batch, the following transactions will occur:
• Any items in the finished goodsʹ and container with a status of Committed will be
relieved from inventory quantities committed to production, and from on‐hand quan‐
tities.
• The finished goods will be added to quantities on‐hand (and quantities on‐order will
be reduced), and actual costs (including material, labor, and overhead costs from the
bills‐of‐materials) will be transferred into the inventory cost file and displayed in the
appropriate cost fields.
• Finished goods lot records will be inserted into the In‐Stock Lot Number (APSERIAL)
file.
• Appropriate information transfers to the production history files and deletes the
records from the current production files.
• Also, the records will be written to the Inventory Pro Distribution to General Ledger
(INDIST) file.
1. These records account for materials and containers used in Production. The Inven‐
tory Offset account is debited (from transaction type‐A production decrement), and
the Inventory Control account is credited (from Inventory class).
2. Additional records account for labor and overhead used. The Labor and Overhead
Offset account is debited (from Labor/Overhead file), and the Labor/Overhead Con‐
trol account is credited (from Labor/Overhead file).
3. Also, INDIST records are written to reflect the finished goods produced. The Inven‐
tory Control account is debited (from Inventory class), and the Inventory Offset
account is credited (from transaction type‐A production increment).
66 Sage PFW
Partially Closing Batches
Note: If your company uses the standard costing method, additional
INDIST records will be written for the variance of material and container
quantity required vs. quantity used for the batch. The Inventory Standard
Cost Variance account (from Inventory class), and the Inventory Offset
account (from transaction type‐A production decrement) are used in this
transaction.
Also, INDIST records are written for the variance of labor and overhead quantity
required vs. quantity used for the batch. The Labor/Overhead Variance account
(from Labor/Overhead file), and the Labor/Overhead Offset account (from the Labor/
Overhead file) are used in this transaction.
The INDIST records written for finished goods produced use quantity‐required
amounts. The Inventory Control account is debited (from Inventory class), and the
Inventory Offset account is credited (from transaction type‐A production increment).
If a WIP account exists in the Formula Class file, Production will use it for the
Production transaction type A increment/decrement and the Labor and Overhead
Offset accounts.
• Finally, any changes that affect inventory will be reflected in the Inventory Transac‐
Chapter 3: Using
tion History (INTXDH) file, and production data will (optionally) be recorded in sum‐
Production
mary or detail in the Production Transaction History (PNTRANH) file, depending on
your choice in the History Tracking Type field, in the Production Application Setup
option.
Regarding Quick-Step Batch Ticket Production

It is not necessary to go through each status of a production order, from New to
Committed to Requisitioned to Finished. It is possible to create a new order, print a batch
ticket, and then immediately close the order if the edit report is not required with no other
intermediate steps required (as long as there were no variances in materials required or
finished goods produced). You are prompted for lot numbers when required, if they have
not been entered automatically.
At the Close Batch option, each step that has not yet been performed is performed, from
New through Committed through Requisitioned, and so forth.
Procedure

Use the following steps to partially close a batch.
Step Actions
1 Open Batch Entry and select the batch that you want to partially
close. For example, the following batch has been entered for 10
each REDOXPRM 55 GAL finished good.
68 Sage PFW
Step Actions
2 Reduce the Quantity Order to reflect the remaining quantity and

add a new line that reflects the quantity that you want to partially
close. This new line item will have a Finished status.
Note: The total of the adjusted Quantity Ordered and

the Quantity Ordered on the new line item should
equal the original Quantity Ordered.
Our example continues, a partial close of quantity 2 of the finished

good must occur to get product out the door. To accomplish this, Fin-
ished Goods line 1 is modified to reduce the quantity to 8 (the
remaining qty ordered) and a second line is added with both quan-
tity ordered and quantity produced as 2. It is important that the qty
ordered from the two line items equal what was originally ordered on
the first line item. (In this case 10 were originally ordered and now
there are two lines of 8 and 2). When you save your changes the sys-
tem will recognize the Finished status on the new line item and create
the finished goods in inventory. It will not relieve raw material inven-
tory although very similar functions can be performed on raw mate-
rial inventory items if needed.
Chapter 3: Using
Production
3 If needed, step 2 can be repeated many times. You must SAVE the
batch in order for the inventory processing to occur.

Step Actions
4 When the batch is completely finished and there is one line remaining
with the 'New' status, you can now close the batch using the Close
Batch menu option. The remaining finished good line will be pro-
cessed as 'Finished', and all the raw material inventory will be
relieved.
70 Sage PFW
Generating a Schedule
Scheduling Production
Description
Production Scheduling is used to automatically schedule batches for production. This
option depends on user‐defined scheduling formulas to analyze current inventory levels
(and sales commitments, if you have installed Order Entry Pro application). From this
data, a schedule of suggested batches is generated to produce. You can review and edit
the scheduled batches before you convert them to actual production orders.
You can also manually enter production schedule records in advance of their start dates.
Then, when itʹs time to start them, you can convert the schedule records to complete,
ready‐to‐print batch tickets with just a few keystrokes.
The Generate Schedule option uses simple logic formulas, which you have defined in
Production Scheduling Formula file maintenance. Using the formulas, a proposed
Chapter 3: Using
schedule of batches is created for production. The Scheduling Formula can support both
Production
make‐to‐order and make‐to‐stock conditions.
Each Production schedule record includes all of the data necessary to convert it into an
actual production order. Each record contains the formula key, finished good item key,
location key, suggested quantity (in finished goods units of measure), suggested start and
finish dates, the customer key (if the schedule resulted from a customer order), and a
comment that identifies the source of the schedule record‐either the Production or MRP
application.
Note: If you have Material Requirements Planning (MRP) application, you will
want to use the Generate Schedule option in that application, exclusively. It auto‐
matically schedules production when customer orders have been entered in the
Order Entry Pro application, or when required by minimum inventory require‐
ments that you have specified in Inventory Pro. In MRP, the scheduling formulas
are built‐in, for truly automated scheduling of purchasing and production.
Procedure
Use the following procedure to generate a schedule:
Step Action
1 Select Generate Schedule from the business desktop.

3 Complete the parameters tabs.


Generate Schedule Window

The following is the Generate Schedule screen.
Item Key Range
Enter the range of item keys that you wish to include in the schedule.
Type
Select Finished Goods to schedule finished goods only. Select Intermediates to schedule
in‐house intermediates only, or select Both to schedule both finished goods and
intermediates.
Note: In Productionʹs Create Schedule option, you can only schedule in‐house
intermediates based on a re‐order point (minimum inventory) that you have
entered in inventory. If you have MRP, it will automatically schedule batches of
in‐house intermediates (pre‐mix) so that they are completed just in time when
they are required in scheduled top‐level batches.
Location Key Range
Enter the range of inventory locations for which you wish to include items for scheduling.
If you have defined only one inventory location, this field may be left blank.
Inventory Class
If you wish to limit this schedule to one class of items, enter the class key. You may leave
this field blank, which will include all of your defined classes in the schedule. Inventory
classes are defined in Inventory Class Description file maintenance.
Note: The following two fields are always prompted for, but are only used if you
have installed Order Entry Pro, and an Order Entry variable (O1 or O2) is
included in your scheduling formula.
Order Entry Request Date Range
Enter the range of Order Entry request dates to be included in the schedule.
72 Sage PFW
Order Entry Order Date Range
The range of Order Entry order dates to be included in the schedule.
Start Date
Enter the date that production orders resulting from this schedule are to be started. The
date that you enter into these fields will appear as the start date of each item in the
Production Schedule file.
Finish Date
Enter the date that production orders resulting from this schedule are to be completed.
The date that you enter into these fields will appear as the finish date of each item in the
Production Schedule file.
Schedule Formula Key
Enter the key identifying the scheduling formula to use when scheduling production
orders. You must enter a key in this field in order to generate a schedule. Scheduling
formulas are defined through Production Scheduling Formula file maintenance.
Append/create Schedule
Enter Create if you wish to replace the existing schedule and create a new one. If you wish
to keep the existing schedule, and append new schedule records to it, enter Append.
Chapter 3: Using
Generate Schedule Sample Report
Production

Generating a Schedule Report

The Schedule Report option displays or prints the schedule records created through the
Generate Schedule option. The Schedule Report groups items by batch and gives a total
batch size so you may determine if a batch needs to be broken up to meet machine or vat
capacities.
Note: You should generate a Schedule Report to verify items that have been
scheduled before using the Create Batches From Schedule option to convert the
schedule to actual production orders.
Procedure
Use the following procedure to print a Schedule Report:
Step Action
1 Select Schedule Report from the business desktop.


Schedule Report Window

The following is the Schedule Report screen.
74 Sage PFW
Generating a Schedule Report
Sort Keys
The Schedule Report option may be sequenced by four different sort‐key combinations,
which will be presented on a Order By submenu as follows:
• Formula Key
• Item Key / Item Location
• Start Date
• Customer Key / Item Key.
Range Fields
Enter the range of the sort key(s) selected from the Order By list, to define the schedule
records to include in this report. The name(s) of the key(s) selected from the Order By list
will complete the names of the range field(s).
Record Status Options
You may leave this field blank to accept the default (zero), which will include only
scheduled orders that have not been processed or you can enter one of the following
options:
Chapter 3: Using
• If you enter 1, then only schedule records, which have had materials only scheduled
Production
will be reported.
• If you enter 2, then only completely processed schedule records (materials and fin‐
ished goods scheduled) will be reported.
Record Type Options
If you do not have the Material Requirements Planning (MRP) application, you may leave
this field blank to accept the default (1), which will include only planned schedule records
in the report. Planned schedule records are those which are based on an actual
requirement, either an inventory reorder point or a customer order.
If you enter 2, then only forecast schedule records will be reported. Forecast schedules are
created by the MRP application, based on historical data, and do not represent actual
requirements. Forecast records are never converted to actual production orders.
If you enter 3, then both Planned and Forecast records will be included in the report.
Schedule Report Sample Report


Correcting the Schedule

The Schedule Entry/Correction option allows you to modify records in the Production
Schedule file that were created using the Generate Schedule option, and to manually enter
schedule records in advance of their starting dates, for planning purposes. You can use
this option to change the scheduled starting dates, and add or delete finished goods from
the suggested batches. You may also adjust the suggested quantities to better suit
production needs, or change the status of the schedule records.
Procedure
Use the following procedure to correct a schedule:
Step Action
1 Select Schedule Entry/Correction from the business

desktop.
cess; or select New to create a new parameter. The
Schedule Entry/Correction window appears.
76 Sage PFW
Step Action
3 A new window displays allowing you to make your

changes.
Select Save when the changes/additions are com-

plete.
Chapter 3: Using
Production
Sort Keys
The Schedule Entry/Correction option may be sequenced by four different sort‐key
combinations, which will be presented on a Order By submenu as follows:
• Formula Key
• Item Key / Item Location
• Start Date
• Customer Key / Item Key.
The Schedule Entry/Correction screen displays the formula key, item key, location key,
quantity scheduled, scheduled start date and time, scheduled finish date and time,
customer key (if the schedule record was based on a customer order), a note entered
identifying the source of the schedule record (either Production Scheduling or MRP
Scheduling), and the status of the record, either 0 (for New), 1 (for finished goods only) or
2 (for fully processed, both materials and finished goods).
When you have examined each schedule record and made corrections as necessary, you
may click the Process button to process the corrections. The schedule may be viewed and
corrected as many times as necessary, until the Create Batches From Schedule option is
used.
Once the Schedule Entry/Correction screen opens, you have access to the two screens. The
following are the field descriptions.

Field Descriptions - Page 1

Each line on this screen represents a separate record in the Production Schedule
(PNSCHED) file. The complete data in these records can also be viewed in Production
Scheduling Line Items file maintenance.
Production schedule records are not deleted when you create batches from the schedule.
Their status is merely changed to 2 (fully processed), which indicates that a batch has been
created from the record. This is the reason that you must purge your schedule records
occasionally, more often if you use the Production Scheduling option frequently.
Formula Key
The formula for which this schedule is being generated.
Item Key
The inventory item, intermediate, or finished good which has been scheduled to be
produced will be displayed here.
Location
The key of the inventory location of the scheduled inventory item.
Quantity
The number of items that have been scheduled for production.
This value is taken from the Quantity to Schedule equation in the scheduling formula
used to schedule this batch.
Start Date/start Time
The date and time this production job is scheduled to begin.
Completion Date/completion Time
The date and time the production job is scheduled to be finished.
Customer Key
The key of the customer for which this batch is being produced will be displayed here.
Comment
This field contains any comments that were entered on the Generate Schedule screen.
Record Status
The record status shown in this field indicates where the item is at in the scheduling
process.
Status Definition
New An item which the scheduling option has
determined is needed to be produced,
but has not yet been converted to a
batch.
Materials Only The scheduling option has scheduled this
Scheduled item, an in-house intermediate, to be pro-
duced and has converted it to a batch.
Processed This item has been fully scheduled and
converted to a batch.
Order Number
The number in this field is the sales order number assigned through Order Entry Pro.
Production Line Id
This option is not used at this time.
78 Sage PFW
Fill Line Id
This option is not used at this time.
Record Type
There are two types of schedule records for this field ‐ planned and forecast. Batches can
be created from planned records, but will not create batches from forecast records.
Refer to the MRP User Guide for additional information regarding planned and forecast
inventory items.
Exclude From MPS
Select Yes if you would like to exclude this item from being taken into consideration by
the Master Production Schedule (MPS). Refer to the MRP User Guide for more information
regarding the MPS.
This field is automatically maintained by the MRP application and should not be changed.
If the MRP application is not installed, this field should be set to No.
Batch Type
The batch type specified in this field designates the manner in which this batch is to be
processed.
Chapter 3: Using
Production
Field Descriptions - Page 2
The following fields shown here are preparatory to the inclusion of process cells and
batch automation. They are not yet used for any purpose.
Formula Key
The formula to be produced by this process cell.
Item Key
The finished good to be produced by this process cell.
Process Cell
Enter the key of the process cell which will be making this batch.
Batch Size
The size of the batch which needs to be produced by this process cell.
Size Unit
This field is used to indicate whether the Batch Size field is measured by Weight or
Volume.
Run Hours
Enter the number of hours which this process cell will require to complete the batch.
Create Own Batch
This field is not used at this time.
Batch No.
You can pre‐assign a batch number to the batch to be produced.
Setup Labor
This field is used to take into account the actual work required to stage the prior to its
production. This usually includes employee wages (or a percentage thereof).
Setup Overhead
This field is used to take into account additional non‐labor related costs required to stage
the batch? prior to its production.

Lot Number
You can enter the lot number of the finished good which will be produced by this process
cell.
Creating Batches From the Schedule

The Create Batches From Schedule option allows you to convert production schedule
records into actual production orders.
Scheduling Both Materials and Finished Goods

Normally you will choose for Both in the Schedule: Materials Only, Finished Goods Or
Both field of the Create Batches from Schedule option. This will enter both materials and
finished goods in the production orders created from schedule records, to produce
complete, all‐in‐one batch tickets.
However, if you have separate production and fill lines, you can split each scheduled
order into separate materials only and fill orders. This two‐step method will create two
batch tickets from each schedule record, one showing all of the ingredients for producing
an intermediate, and the other showing the finished goods being produced for the
intermediate, including the specified container and bill‐of‐materials items (labels, cartons,
etc.) This method is described as follows.
Creating Separate Materials Only and Fill Orders (The Two-Step Method)
If you wish to create separate batch tickets for production and fill operations from the
same schedule record, you must first set up a material item record, through the Inventory
Pro Item Entry, with an item key the same as the formula key. This record will reflect the
on‐hand quantity of the bulk formula, temporarily, until you use the same schedule
record to create a fill order. A material item record must be set up for each formula that
you wish to stock as a bulk formula. To use this material in the fill order, it must have an
item key the same as its formula key, just like a true intermediate, although it isnʹt
necessary for these bulk formula material item records to be flagged as in‐house
intermediates. The bulk material item key will appear as the only ingredient on the fill
order.
The two‐step method is performed by entering the Schedule: Materials Only, Finished
Goods Or Both field of the Create Batches from Schedule option, as follows:
Step 1 - Enter Materials Only
Use this option to create a batch of a formula to be stored, temporarily, as bulk inventory.
When this field is set to Material Only, the formula/bulk material key is entered as the
finished good, and when the batch is completed, you will have an on‐hand quantity of the
bulk material in the inventory location record that you set up for this purpose, above. In
other words, you will have a quantity of the formula on hand.
80 Sage PFW
Step 2 - Enter Finished Goods
After you have created a materials only batch ticket, as described above, then you can
create a fill order from the same schedule record. This time, you will enter Finished Goods
only in this field. The formula line item screen for this batch will have only one ingredient,
the bulk product that was processed in Step 1. Note that you cannot create a finished
goods only batch until you have first created a materials only batch, if you are using the
two‐step method.
Note: Use the two‐step method, described above, if you wish to create separate
production and fill tickets for each scheduled order. You can also schedule
batches to produce bulk products to maintain a minimum inventory, and then
create fill orders manually. This is called the one‐step method, which is also used
to create batches from schedule for the production of in‐house intermediates.
Creating Batches for Intermediates and Bulk Products (The One-Step Method)
It is not necessary to use the two‐step method described above when you are creating
batches from schedule for true intermediates, or bulk products which are not correlated to
particular fill orders. For this one‐step process, you must set up a material item record,
Chapter 3: Using
using the Inventory Pro Item Entry, with an item key matching the formula key. Also, you
Production
must set the Intermediate Type field to I (for In‐house intermediate). This is required for
true intermediates, so that it will recognize them as such in several options.
Then, when you run the Create Batches from Schedule option, you will set the SChedule:
Materials Only, Finished Goods Or Both field to Both materials and finished goods.
Although we wish to produce the bulk product or intermediate material only, we select
Both in this field, which considers this schedule record fully processed, since we do not
wish to save the schedule record to create a matching fill order. The finished good for
this order will be the bulk formula or intermediate item key, which matches the formula
key.
The only difference, from the two‐step method described above, is that this schedule
record will not be available to create a matching fill ticket after you have created the
production batch. When the batch is completed, you will simply have an on‐hand
quantity of the intermediate, or bulk formula, in stock. You can use the intermediates as
ingredients, and the bulk products (sometimes called tank stock) to fill orders from
inventory, by either of the following methods:
Fill From Inventory?

The Fill From Inventory checkbox is enabled when you enter a formula key in the Batch
Entry option that has an inventory item key matching the formula key. If you select the
Fill From Inventory checkbox, the batch will have only a single ingredient, the bulk
material item key. You can commit the bulk material to production, and requisition it just
like any other raw material.
The Fill From Inventory checkbox will be enabled whether or not you have enough of the
bulk formula on hand to fill the order. Any shortage will be reported just like a normal
raw material. However, if the bulk formula item key is found in more than one inventory
location, you will be prompted to select the location from which you wish to fill this order.
If you do not select the Fill From Inventory checkbox, the master formula is copied to the
production order, and ignore any bulk inventory.

Scheduling Finished Goods Only (The Half Step)

There is a third method, if you prefer to create batch tickets from schedule for Step 2 (the
fill process, described above), without first having created batch tickets for Step 1, the
materials only step. This procedure assumes that you maintain a minimum inventory of
bulk products, as described above, and that you have sufficient quantity of the bulk
formula on hand to fill the order(s). Remember that these bulk products must have an
inventory item key matching the formula key, so that you can use them in place of the
formula ingredients.
To create a finished‐goods‐only batch from a schedule record that was not used to
produce the materials, you must manually change the status of the schedule record(s)
from 0 (New) to 1 (Materials Only), using the Enter/Correct Schedule option. Then, when
you run the Create Batches from Schedule option, you can select Finished Goods Only,
and the scheduled finished goods will be specified on the batch ticket. There will be only
one formula ingredient on this type of order, which will reflect the bulk product item key.
To use this option, you must have previously set up a material item record in Inventory,
using the Item Entry. Like an intermediate, this item record must have the same key as the
formula key; however, you do not have to identify the item record as an in‐house
intermediate, since you will not be rolling up costs or physical properties for these items.
Note: When you create batches from schedule with a formula that has a process
cell key, the process cell information is automatically entered in the scheduled
production order.
When you select Create Batches From Schedule from the Production Scheduling menu,
you will see the parameter maintenance screen similar to the following illustration.
82 Sage PFW
Field Maintenance
Schedule: Materials/finished Goods /both
Normally you will set this field to Both, so that raw materials and finished goods will both
be specified in the batches created from schedule. The Materials and Finished Goods are
used for the two‐step method of splitting scheduled orders into two separate batch tickets,
one for materials only and another for the fill order, as explained above. Use the Lookup
button next to the field to make your selection.
Maximum Batch Size
Enter a number to designate the maximum size of any batch that can be processed at your
facility. This field must have data entered in order to process the schedule. For example, if
you have a 500 gallon vat, you would enter 500 here, and identify the unit of measure in
the following field as Volume. This will place an upper limit on the size of the batch will
create a batch ticket for at any one time. If the total batch exceeds the volume of the mixing
container, multiple batch tickets will be scheduled.
Note: Normally, scheduled orders with the same master formula are combined,
up to the size of the maximum batch that you specify here. If you enter 0 (zero),
one batch will be created for each schedule record; i.e., orders will not be com‐
bined.
Chapter 3: Using
Production
Unit Of Measure
Indicate whether the maximum batch size that you entered, above, is measured by weight
or volume.
Use Loss Factor / Constant
Indicate whether the loss factor and loss constant that you have defined for each formula
shall be included in the calculation of maximum batch size.
Use Order Number As Batch Number
If this schedule record was created as a result of a customer order in Order Entry Pro, you
may select Yes to assign a batch number based on the order number. If you select No, then
the next sequential batch number, as specified in the Production Application Setup, is
assigned.
Note: If you enter Y (for Yes) in this field, each schedule record will result in a
separate batch ticket; i.e., small orders will not be combined.
For example, if the auto‐increment portion of the Order Entry Pro ‐ Sales Order Number
mask is defined as xxxxxxxxx and there are more than 99 lines in the sales order,
production batches will be created with batch numbers as follows: 000000070‐01 through
000000070‐99, the next number is assigned as 000000070‐01A, 000000070‐01B, through
000000070‐01Z. The next number assigned is 000000070‐01AA, 000000070‐01AB,
000000070‐01AC through 000000070‐01AZ, 000000070‐01BA, etc.
Batch Completion Date: Use Schedule Completion Date Or Leave Blank
Select Schedule Date if you wish to use the date entered by the scheduling option for the
Completion Date field on the order. If you would rather leave the Completion Date field
blank, select blank in this field. Then, you will have to enter the completion date
manually, in the Batch Entry option.
Formula Key Range
You may restrict the batches created from schedule to a single formula, or a range of
formulas.

Start Date Range
You may further restrict the batches created by entering a date or date range. Only those
batches scheduled to start within this date range will be created.
Customer Key
You may restrict the batches created to one customer, if you wish. If you want the
scheduled batches created for every customer in the schedule file, leave this field blank.
Intermediate Location
If scheduling ʹMaterials Onlyʹ, then enter a ʹfinished goodʹ location to be assigned to the
Intermediate items produced.
84 Sage PFW
Purging Schedule Records
Description
The Purge Schedule Records option erases all fully‐processed records from your
Production Schedule (PNSCHED) file.
Procedure
Use the following procedure to purge schedule records:
Step Action
1 Select Purge Schedule Records from the business desk-

top.
Chapter 3: Using
Production
Purge Schedule Records Window

The following is the Purge Schedule Records screen.

Purge Forecast Records

You will be prompted to specify whether or not you wish to purge forecast schedule
records. Forecast records are created by the Material Requirements Planning (MRP)
application, based on historical sales or historical production data. Refer to the MRP User
Guide for more information regarding forecasting.
Note: If you have not installed MRP application, you can ignore this prompt.
If you have the MRP application, this switch is provided so that you do not have to delete
your forecast records when you purge planned schedule records that you have converted
into batches. Forecast records are never converted into batches, so you will want to purge
them at regular intervals to avoid disk space being filled up with old forecast records.
If you select Yes to purge forecast records (as well as planned schedule records), you will
be prompted to enter a date through which you wish to purge forecast records. You can
use the lookup to select the desired date.
86 Sage PFW
Chapter 4:
Generating Reports and Listings
Introduction
This chapter provides information about Production reports and listings including
sample output.
Reference
For report generating instructions, refer to the System Basics User Guide.
In this chapter
Topic Page
Reports 88
Listings 123
Chapter 4: Generating
Reports and Listings

Reports
Description
Production provides the following predefined reports:
• Batch in Process Report
• Committed Batch Report
• Container Usage Report
• Container Where Used in Process Report
• Critical Materials Report
• Finished Good Lot Explosion Report
• Finished Goods in Process Report
• Finished Goods Production Report
• Formula Production Report
• Lot Recall Report
• Material Lot Number Explosion Report
• Material Variance Report
• Material Where Used in Process Report
• Production Cost Summary Report
• Production History Report (Detail)
• Production History Report (Summary)
• Production Master Report
• Raw Material Usage Report
• Schedule Report
Batch in Process Report

The Batch In Process Report allows you to view or print a listing of all production orders
which are currently being worked on, but have not yet been closed. It also allows you to
determine if any materials, which have been committed still remain to be used.
Procedure
Use the following procedure to generate a Batch in Process report:
Step Action
1 Select Batch in Process Report from the business desk-

top.

88 Sage PFW
Committed Batch Report
Batch in Process Report Window

The following is the Batch in Process Report screen.
Sort Keys
You can choose to sequence the report by batch number and formula key, or formula key
and batch number.
Parameter Fields

Range Fields
Define the range of batch numbers or formula keys that you wish to include in the report.
Use the Lookup button next to the field to make your selection.
Report Contents
The Batch In Process Report lists the batch number, formula key, description, start date,
finished date, days late, total batch weight, total batch volume, status, and customer key,
for each batch. To view a sample report, click the following button:
Committed Batch Report

The Committed Batch Report allows you to view or print a report of those production
orders which have a status of Committed.

Procedure
Use the following procedure to generate a Committed Batch Report:
Step Action
1 Select Committed Batch Report from the business

desktop.

Committed Batch Report Window

The following is the Committed Batch Report screen.
Sort Keys
The report may be sequenced by the batch number alone, or by the item key/ location key/
batch number.
Parameter Fields
Define the range of batch numbers (or item keys, location keys and batch numbers, if you
chose those sort keys), of the production orders you wish to include in the report.
90 Sage PFW
Container Usage Report
Report Contents
When sequenced by batch number, the report includes the batch number, formula key,
start date and completion date for each batch reported. Then, the item key for each
formula line item that has a status of Committed will be listed, along with its location key,
line type, description and quantity committed.
When the report is sequenced by item key, location key and batch number, the description
of each raw material which has been committed to a batch within the range of batch
numbers defined will be listed, along with the item key, location key, line type (always
inventory, in this report), the batch number, formula, weight committed, start date and
completion date. To view a sample report, click the following button:

The Container Usage Report lists consumption levels for one or more containers over a
specified range of dates. The report may be restricted to a particular container class and/or
status.
Procedure
Use the following procedure to generate a Container Usage Report:
Step Action
1 Select Container Usage Report from the business desk-

top.


Container Usage Report Window

The following is the Container Usage Report screen.
Sort Keys
The report can be sequenced by the item (container) keys plus location keys.
Parameter Fields
Enter the data fields as described below to define a report.
Range Fields
Define the range of item (container) keys and location keys that you wish to include in the
report.
Item Class
If you have set up more than one class of containers, and you wish to limit this report to
one class of containers, select the class key, or select a class key from the lookup window.
You can leave this field blank to report all of your defined classes. Container classes must
have previously been defined in the Inventory Class Description file maintenance menu
item.
Item Status
If you wish to limit this report to one status of containers, select the status key, or select a
status from the lookup window. You can leave this field blank to report all of your defined
statuses. Container statuses must have previously been defined in the Inventory Status
Description file maintenance menu item.
Activity Date Range
Enter the range of dates during which this container was used for which you would like to
include on this report.
Break On Location
Select Yes to print the data for each location on a separate page.
92 Sage PFW
Print Item Descriptions
Select Yes if you want to include the container descriptions in the report. Select No if you
do not want to include the container descriptions.
Note: If you have a large number of containers, you may wish to select No in this
field to save space and paper.
Use Last / Average / Standard Costs
Select L (for Last), A (for Average), or S (for Standard) to select the cost method to be used
on the report.
Average costs and quantities are calculated as follows:
Total cost for Total Qty for

Avg. Cost/Year = period x 365 Avg. Qty/Year = period x 365
No. of days of No. of days of
data found data found
Avg. Cost/Month = Avg. Cost/Year Avg. Qty/ = Avg. Qty/Year

12 Month 12
If a transaction with a date on or before the Activity Date Range: Begin Date was not
found, the item will be flagged with an asterisk, and the report will include a footnote as
follows:
• * = Data range found was shorter than date range requested.
• Averages may not be reliable.
Include Active / Inactive / Every Item
Select Active if you wish to report only active containers, Inactive for inactive containers,
or Every Item for every container in the range of containers and locations specified above.
• Active means that the item was used during the specified period.
• Inactive means that the item was not used during the specified period
• Every Item means that the range of containers and locations defined above will be
reported, without regard to whether they were used or not during the activity date
range.
Report Contents
The Container Usage Report displays the item key, description (if selected), location key,
container cost, total cost and quantity used for the date range, average cost and quantity
per month, and average cost and quantity per year. To view a sample report, click the
following button:

Container Where Used in Process Report

The Container Where Used In Process Report shows each container that is currently in use
by an open batch, the quantity of the containers required, and the quantity of containers
used. If a container is tracked by lot number, the lot numbers and lot quantities will be
reported as well.
Procedure
Use the following procedure to generate a Container Where Used in Process report:
Step Action
1 Select Container Where Used in Process Report from

the business desktop.

Container Where Used in Process Report Window

The following is the Container Where Used in Process Report screen.
Sort Keys
Data can be sequenced on the Container Where Used in Process Report by the item key
and location key.
94 Sage PFW
Critical Materials Report
Parameter Fields
Enter the range of item (container) keys and location keys that you wish to include in the
report.
Report Contents
The Container Where Used in Process Report lists the container description and item key,
location key, batch number, quantity ordered, quantity committed, quantity
requisitioned, and lot numbers, if any, followed by lot quantities. To view a sample
report, click the following button:
Critical Materials Report

The Critical Materials Report allows you to view or print a list of materials which have an
insufficient quantity on hand to fill current production orders. This report calculates the
total quantity of items required in the range of items, batches and locations defined,
including only those line items with a status of either New or Committed. Items which
have already been requisitioned are ignored. This quantity is then compared to each item/
locationʹs quantity on hand. If the quantity required is greater than the quantity on hand,
the difference is reported as Critical.
Procedure
Use the following procedure to generate a Critical Materials report:
Step Action
1 Select Critical Materials Report from the business desk-

top.


Critical Materials Report Window

The following is the Critical Materials Report screen.
Sort Keys
Data can be sequenced on the Critical Materials Report by the batch number plus formula
key.
Parameter Fields
Define the range of batch numbers, formula keys, item keys, location keys, order date,
start date and complete date of the production orders you wish to include in the report.
Report Contents
The Critical Materials Report lists the item key, description, location key, batch number,
formula key, start date, quantity required, quantity on‐hand, projected quantity short, and
unit of measure. To view a sample report, click the following button:
Finished Good Lot Explosion Report

The Finished Goods Lot Explosion report lists a single lot of a lot‐tracked finished good,
and then reports any lot‐tracked ingredients which were components of that lot of
finished goods. The source file for this report is the Production Lot Number History
(PNLOTH) file. If you need to know which lot‐tracked ingredients went into a particular
batch or finished good lot, this report will tell you.
96 Sage PFW
Finished Good Lot Explosion Report
Procedure
Use the following procedure to generate a Finished Good Lot Explosion report:
Step Action
1 Select Finished Good Lot Explosion Report from the

business desktop.

Finished Good Lot Explosion Report Window

The following is the Finished Good Lot Explosion Report screen.
Sort Keys
Data may be listed on the Finished Good Lot Explosion Report by either batch number(s)
or raw material item key(s). These are not ordinary sort keys, since the only fields on the
data‐entry screen for this report are the finished good Item Key and finished good Lot
Number fields, regardless of which sort key you select.
The sort keys actually provide two different reports, using the same data sorted in two
different ways.
• When you select Batch Number from the Sequence‐By list, the finished good and lot
number combination that you select on the screen will be displayed at the top of your
report, and each batch number that produced the finished goods which make up the
finished good lot will be listed, along with raw material quantities and lot data.

• When you select Item from the Sequence‐By list, the finished good and lot number
that you select on the screen will be displayed the at the top of your report, and each
lot‐tracked raw material item that went into the finished‐good lot will be listed in
sequence, along with the applicable batch number, and raw material data.
Parameter Fields
Enter the finished good key and lot number on which you wish to base the report.
Report Contents
The Finished Good Lot Explosion Report displays the finished good item key, lot number,
and location key at the top of the report. The report then lists the batch number(s) which
produced the finished goods in that lot and any lot‐tracked ingredients in the finished
good, by raw materials item key, location key, lot number, and quantity in the batch.
Finished Goods In Process Report

The Finished Goods In Process Report allows you to view or print a list of those finished
goods which are currently in process in open production orders. This report is similar to
Batches In Process Report, but only includes data on the finished goods.
Procedure
Use the following procedure to generate a Finished Goods in Process report:
Step Action
1 Select Finished Goods in Process Report from the busi-

ness desktop.

98 Sage PFW
Finished Goods Production Report
Finished Goods in Process Report Window

The following is the Finished Goods in Process Report screen.
Sort Keys
When you select Finished Goods In Process from the Production menu, you can choose to
sequence the report by the batch number and finished good key, or the finished good key
and batch number. Both of these fields will appear on the parameter maintenance screen,
the difference being the one you choose as the primary sort key, which will be listed first
on the screen.

Parameter Fields
Define the range of finished good keys that you wish to include in the report.
Report Contents
The Finished Goods in Process Report lists the batch number, comments (if any were
selected on the Finished Good screen of the Create/Update Production Order option),
completion date, finished good key, location key, customer key, status, quantity ordered
and quantity produced.
Finished Goods Production Report

The Finished Goods Production Report lists production quantities and cost data for one or
more finished goods and locations, over a user‐defined range of dates. The report may be
restricted to a particular item class and/or status.

Procedure
Use the following procedure to generate a Finished Goods Production report:
Step Action
1 Select Finished Goods Production Report from the busi-

ness desktop.

Finished Goods Production Report Window

The following is the Finished Goods Production Report screen.
Sort Keys
The report can be sequenced by finished good key, location key, and the activity date
range.
Parameter Fields
Range Fields
Select the range of finished goods, location keys and activity dates that you wish to
include in the report.
Item Class
If you wish to limit this report to one class of finished goods, you can select just that class
key. You can leave this field blank, to report all of your defined classes. Item classes must
have previously been defined in Inventory Class file maintenance.
100 Sage PFW

Formula Production Report
Item Status
If you wish to limit this report to one status of finished goods, you can select just that
status key. You can leave this field blank, to report all of your defined statuses. Production
finished good statuses must have previously been defined in the Inventory Pro Item
Status Description file maintenance menu item.
Break On Location
Select Yes to cause each finished good to print on itʹs own page.
Print Finished Good Descriptions
Select Yes if you want to include the finished goods descriptions on the report. Select No if
you do not want to include the finished goods descriptions. If you have a large number of
finished goods, you can select No in this field to save space and paper.
Select Standard, Average, or Last to select the cost method for the report.
Select Active if you want to include only active finished goods, Inactive for only inactive
finished goods, or Every for every finished good in the range of finished goods and
locations specified above.
• Active means that the finished good was produced during the specified period.
• Inactive means that the finished good was not produced during the specified period
• Every Item means that the range of finished goods and locations defined above will be
reported, without regard to whether they were produced or not during the activity
date range.
Report Contents
The Finished Goods Production Report lists the finished good key, description (if
selected), location key, cost of materials per finished good unit, finished good unit of
measure, date range cost and quantity, average cost and quantity per month, and average
cost and quantity per year.
Formula Production Report

The Formula Production Report lists formula production quantities and cost data for one
or more formulas over a range of specified dates.

Procedure
Use the following procedure to generate a Formula Production report:
Step Action
1 Select Formula Production Report from the business

desktop.

Formula Production Report Window

The following is the Formula Production Report screen.
Sort Keys
Data can be sequenced on the Formula Production Report by the formula key range.
Parameter Fields
Range Fields
Define the range of formula keys and dates of production that you wish to include in the
report.
Formula Class
If you wish to limit this report to one class of formulas, select just that class key. You can
leave this field blank to report all of your defined classes. Formula classes must have
previously been defined in Formulas Class Description file maintenance.
102 Sage PFW

Lot Recall Report
Formula Status
If you wish to limit this report to one status of formulas, select just that status key. You can
leave this field blank to report all of your defined statuses. Formula statuses must have
previously been defined in Formulas Status Description file maintenance.
Note: If you choose Active status, only formulas with a quantity produced
greater than 0 are included on the report.
Activity Date Range
Enter the range of dates during which this formula was produced which you would like
to include on this report.
Report By Weight Or Volume
Select whether you want to view the reported quantities by weight or by volume.
Select whether you want to include only active formulas, inactive formulas, or every
formula in the range of formulas specified above.
• Active means that the formula was produced during the specified period.
• Inactive means that the formula was not produced during the specified period
• Every Item means that the range of formulas defined above will be reported, without
regard to whether they were produced or not during the activity date range.
Print Formula Descriptions On Report
Select Yes if you want to include the formula descriptions on the report. Select No if you
do not want to include the formula descriptions. If you have a large number of formulas,
you may wish to select No in this field to save space and paper.
Report Contents
The Formula Production Report lists the formula key, description (if selected), material
cost, total cost and quantity (weight or volume), for the date range, average cost and
quantity (weight or volume) per month, and average cost and quantity (weight or
volume), per year.
Lot Recall Report

The Lot Recall report addresses the new Bioterrorism Act of 2002 requirements. The Lot
Recall report displays customer contact and shipment information for all products sold
for which the selected item and lot was a raw material, either directly, or indirectly
through intermediate production.
For example, a raw beef lot might be an ingredient in an intermediate chopped meat
batch, which itself becomes an ingredient to hamburgers. In this case, if the raw beef lot is
to be reported on, we must find the disposition of the intermediate chopped meat batch
and all of the subsequent hamburger or other lots created from that intermediate, along
with the disposition of any remaining raw beef.

In addition, the Lot Recall report provides vendor contact and shipment information. In
the above example, if the hamburger lot is to be reported on, the report can identify the
vendor supplying the ingredients of the hamburger lot as well as the vendor supplying
the ingredients of the intermediate chopped meat batch.
Setup Requirements
To use this report, there are several setup requirements. They are as follows:
• The Lot Recall report can only be used with lot numbers, therefore Lot Number track‐
ing must, at a minimum, be used for any item for which recalls are possible. The
report will not work with Bin numbers or SSCC numbers alone.
• The FDA requires that transporter’s name and address information be included on the
report. The transporter’s address and contact information will only be printed if a
Vendor is defined with a Vendor Key identical to the related Ship Via key in both AP‐
Ship Via file maintenance and AR‐Ship Via file maintenance. For example, if you have
a Ship Via key of UPS, you must add a vendor record for UPS in the Vendor file main‐
tenance.
• Per FDA requirements, records must be retained for a minimum of 2 years, therefore
users must be careful about purging the tables used by this report, discussed in the
following section.
• Lot numbers and SSCC number combinations should always be unique for the same
item.
Data file usage

The Lot Recall report uses data from the following tables:
Table Name Function

APSERIAL Contains current lot status information for all in-stock purchased lots as
well as all lots for in-stock in-house intermediates and by-products.
PNLOTH Contains lot transaction production information for produced lots.
ARSERIAL Contains lot transaction sale information for all sold lots.
INSERLTX Contains a transaction record for every lot transaction activity from all
applications.
• For Purchased Lots, Transaction Type = P, Transaction Qty is positive
• For Produced Lots, Transaction Type = A, Transaction Qty is positive
• For Production Usage Lots, Transaction Type = A, Transaction Qty is

negative
• For Sold Lots, Transaction Type = S, Transaction Qty is negative.
Note: This report associates Original Quantity with a Pur-

chase/Sale/Production/Return activity only, not anything
else because only these activities involve a transaction with
outside Vendor/Customer. Therefore, Move (M) type trans-
actions do not effect the Original Quantity.
INMAST Contains product information.

ARCUST Contains customer address information.
APVEND Contains vendor address information.
ORHDR Contains ship via information for sales orders.
104 Sage PFW

Lot Recall Report
ORLINH Contains sales order item shipment information.

PUHDR Contains ship via information for purchase orders.
PULINH Contains purchase order item receipt information.
Procedure
Use the following procedure to generate a Lot Recall report:
Step Action
1 Select Lot Recall Report from the business desktop.


Lot Recall Report Screen

The following is the Lot Recall Report screen:
Sort Keys
The Lot Recall report has four Order By choices. These choices are:
• In‐stock Lots
• Sold Lots
• Production History Lots
• All Lots

Note: The Order Byʹs on the parameter screens indicate only which lookups are
available, and have no bearing on the actual report sequence or sorting. Each sec‐
tion of the report is sorted by Item Key/Lot Number/SSCC.
Parameter fields
Every item key is assigned an item type. Based on the item type of the item selected for the
report, specific information is included on the report.
Item Type Information included on the report:

Raw • In-stock quantities for requested lot plus all by-products, in house
Material intermediates, and finished goods produced from the selected
Raw Material.
• Vendor Address and purchase information for the Vendor from
whom the lot was purchased.
• Transporter Address information for the Vendor that transported
the lot from the selling vendor to the reporting company.
• Product and Customer Address information for all sales of the Raw
Material Lot, or of any By-Products, In-House Intermediates, or Fin-
ished Goods
produced from the Raw Material Lot, along with date, quantity
and UOM information of the sale.
the lot from the reporting company to each customer.
Finished Good • In-stock quantities for requested lot.
• Customer Address information for all sales of the Finished Good Lot,
including date, quantity and UOM information of the sale.
• Product and Vendor Address information for all purchases of Raw
Materials related to the production of the Finished Good lot, or of
any In-House Intermediates related to the production of the Fin-
ished Good lot, or of any ingredients of the Finished Good lot,
including date, quantity, and UOM information of the purchase.
the lot from the vendor to the reporting company.
106 Sage PFW

Lot Recall Report
By-product • In-stock quantities for requested lot plus all by-products, in house
intermediates, and finished goods produced from the selected By-
product
• Customer Address information for all sales of the By-product Lot, or
any
By-products, In-house Intermediates, or Finished Goods produced
from the
By-product lot, including date, quantity and UOM information of
the sale
Materials related to the production of the By-product lot, or of any
In-House Intermediates related to the production of the By-product
lot, or of any ingredients of the By-product lot, including date,
quantity, and UOM information of the
purchase.
the Raw Materials determined above from the selling vendor to the
reporting company.
• Product and Customer Address information for all sales of all Fin-
ished Goods in which the By-product Lot was an ingredient, at any
level, including date, quantity and UOM information of the sale
the lots determined above from the reporting company to each
customer.
In-house Inter- • In-stock quantities for requested lot plus all by-products, in house
mediate intermediates, and finished goods produced from the selected
Intermediate.
• Customer Address information for all sales of the In-House Interme-
diate Lot or of any By-Products, In-House Intermediates, or Finished
Goods produced from the In-House Intermediate Lot, including
date, quantity and UOM
information of the sale
• Transporter Address information for the selling Vendor that trans-
ported the lot from the reporting company to each customer.
Materials related to the production of the By-product lot, or of any
In-House Intermediates related to the production of the By-product
lot, or of any ingredients of the By-product lot, including date,
quantity, and UOM information of the
purchase.
the Raw Materials determined above from the vendor to the
reporting company.
• Product and Customer Address information for all sales of all Fin-
ished Goods in which the By-product Lot was an ingredient, at any
level, including date,
quantity and UOM information of the sale
the lots determined above from the reporting company to each
customer.

Report Content
The Lot Recall report lists information about the source of all purchased items related to
the selected lot, a list of all recipients of products derived from the selected lot, and the on
hand quantities of the selected lot, or of any products in which the selected lot was an
ingredient.
Material Lot Number Explosion Report

The Material Lot Number Explosion report lists a single lot of a lot‐tracked raw material,
and then reports the finished good lot number(s) and batch number(s) that have used the
raw material from that particular lot. The source files for this report are the Production
Lot Number History (PNLOTH) file, and the Inventory Pro In‐Stock Lot Number
(APSERIAL) file. If you need to know where a particular lot of raw material ended up, this
report will tell you.
Procedure
Use the following procedure to generate a Material Lot Number Explosion report:
Step Action
1 Select Material Lot Number Explosion Report from the

business desktop.

108 Sage PFW

Material Lot Number Explosion Report
Material Lot Number Explosion Report Window

The following is the Material Lot Number Explosion Report screen.
Sort Keys
Data may be listed on the Material Lot Number Explosion Report by either batch
number(s) or item key(s). These are not ordinary sort keys, since the only fields on the
data‐entry screen for this report are the material Item Key field and material Lot Number
field, regardless of which sort key you select.
The sort keys actually provide two different reports, using the same data presented in two
different ways.
• When you select Batch Number, the raw material item key and lot number combina‐
tion that you select on the screen will be displayed at the top of your report, and each
batch number that used material from that particular lot will be listed, along with fin‐
ished good item keys (and lot numbers, if the finished good is lot tracked), and the
quantity filled.
• When you select Item from the Sequence‐By list, the raw material item key and lot
number that you select on the screen will be displayed the at the top of your report,
and each finished‐good item key (and lot number, if any) which used the material
from the particular lot will be listed in sequence, along with the finished good location
key, the applicable batch number, and the quantity filled.
Parameter Fields
Enter the material item key and lot number on which you wish to base the report.
Note: To locate the desired lot number in the lookup, you must first select an item
key. This will restrict the displayed lot numbers to those associated with the
selected item key.

Report Contents
The Material Lot Number Explosion Report lists the following information for the
selected inventory item: item key, location key, lot number, purchased from, purchase
date, and purchase order number.
The report also lists the following information for each batch or finished good in which
this material is used: the batch number, weight used in batch, finished good item key,
finished good location key, finished good lot number, and the number of finished goods
filled.
Material Variance Report

The Material Variance Report allows you to review variations in ingredient levels which
have occurred in past production jobs. The Material Variance Report shows actual raw
material usage relative to the standard quantities of the master formula. The report may
also be generated to show actual yield, and compare that to the yield that theoretically
should have been attained.
Procedure
Use the following procedure to generate a Material Variance Report:
Step Action
1 Select Material Variance Report from the business

desktop.

110 Sage PFW

Material Variance Report
Material Variance Report Window

The following is the Material Variance Report screen.
Sort Keys
You can choose to sequence the report by the batch number alone, or by the item key,
location key and batch number.
Parameter Fields

Enter the data fields as explained below to define a Materials Variance Report. Enter a
parameter key and description if you intend to save the parameter record for future use.
Range Fields
Define the range of batch numbers (or item keys, locations and batch numbers), that you
wish to include in the report. The titles of these fields depend on your choice of sort keys
from the Sequence‐By list.
Minimum Percentage Of Variance To Report (.2 = 20%)
Enter the minimum amount of variance in usage that you want to use to search for when
determining what materials to include in the report. Enter percentages as decimals.
Report Contents
The Material Variance Report lists the batch number, item key, location key, quantity
requisitioned, quantity used, and percent variance.

Material Where Used In Process Report

The Material Where Used In Process Report displays a user‐defined list of raw materials
that are currently in process in open production orders, and then lists each batch number,
the quantity of the raw material required, the quantity committed, and the quantity
requisitioned. If a raw material is tracked by lot number, the lot number and lot quantity
used will be reported as well.
Procedure
Use the following procedure to generate a Material Where Used in Process report:
Step Action
1 Select Material Where Used in Process Report from the

business desktop.

Material Where Used in Process Report Window

The following is the Material Where Used in Process Report screen.
Sort Keys
Data can be sequenced on the Material Where Used in Process Report by the item key,
location key and batch number.
112 Sage PFW

Print Pick List
Parameter Fields
Enter the item keys, location keys, and batch number(s) to define a particular report.
Report Contents
The Material Where Used in Process Report lists material items which are currently
required in production, the item location, batch number, quantity required, quantity
committed, quantity requisitioned and lot numbers, if any, followed by lot quantities.
Print Pick List

The Print Pick List option allows you to print a list of the materials needed to fill
production orders. Covering a range you establish by setting parameters, the Print Pick
List reports cover batch number, item key, SSCC, location, quantity, bin, and unit‐of‐
measure.
Using the Print Pick List option, you can produce a list that can be used to retrieve or
assemble the materials needed to fill a production order or batch ticket. Because the
contents of the report can be sorted by parameters such as location or bin, a person can go
to a specific storage area and gather needed materials for several different production
orders at the same time.
Procedure
Use the following procedure to generate a Print Pick List:
Step Action
1 Select Print Pick List from the business desktop.



Print Pick List Window

The following is the Print Pick List screen.
Sort Keys
You can sort the pick list by item key and location, by location and bin number, and by
batch number. These are selected in the Order By fieldʹs drop‐down box.
Parameter Fields
The Print Pick List window consists of three tabbed pages that allow you to select various
ranges of parameters for selecting items to pick.
• Location/Item Key Filter
Location Key Range
Bin Number Range
Item Key Range
• Batch Number/Customer Key Filter
Order Number
Customer Key
• Date Range Filter
Start Date Range
Complete Date Range
Order Date Range
114 Sage PFW

Production Cost Summary Report
Production Cost Summary Report

The Production Cost Summary Report provides a list of finished goods which have been
produced during a user‐defined period, and the associated costs required to produce
them. This will allow you to compare product cost data from batch to batch.
Procedure
Use the following procedure to generate a Production Cost Summary Report:
Step Action
1 Select Production Cost Summary Report from the busi-

ness desktop.

Production Cost Summary Report Window

The following is the Production Cost Summary Report screen.
Sort Keys
Data may only be sequenced on the Production Cost Summary Report by the batch
completion date.
Parameter Fields
Enter the data fields as explained below to define the report.

Date Completion Range
Define the range of batch completion dates of the production orders you wish to include
in the report.
Location Key
Select a location if you wish to restrict the report to just one of your finished goods
locations. Leave this field blank to include all finished goods locations. If you select a
location key in this field, the report will include finished goods which have that location.
Report Contents
The Production Cost Summary Report displays the finished good key, finished good
location key, batch number, date batch completed, raw material cost, container cost, labor
and overhead cost, total batch cost, total quantity produced, and the unit cost.
Subtotals for the materials cost, container cost, labor and overhead, and total batch costs
are shown below each column.
Production History Report (Detailed)

This option allows you to report on various aspects of your production history in
complete detail. This report is identical to the Production History (Summary) Report.
Note: When the Cost Adjustment (E type) transaction is posted for the raw mate‐
rial, after requisitioning or closing the batch, it does not update files in produc‐
tion. Therefore Production History Report (Detailed) does not reflect the change
in the raw materialʹs cost.
Once a production batch is requisitioned or closed, no changes to the history can be made.
Therefore the Production History Report (Detailed) do not get updated with any cost
adjustment.
Procedure
Use the following procedure to generate a Production History Report:
Step Action
1 Select Production History Report from the business

desktop.

116 Sage PFW

Production History Report (Detailed)
Production History Report (Detailed) Window

The following is the Production History Report screen.
Sort Keys
This report can be sequenced by batch number, formula key, responsibility key, customer
key and date complete. All of these keys will appear on the parameter maintenance
screen; however, you can choose any one of them as the primary sort key. The key you
choose from the Order‐By list will appear first among the sort keys on the parameter
maintenance screen. The other keys will be secondary sort keys.

Note: The parameters that were saved for this report include exclamation points
in the range field. These cause a prompt to display asking you for the range of
batch numbers (in this example), or formula(s), customer key(s), etc., depending
on which one you chose from the Sequence‐By list, above.
Then, when you choose a previously‐defined report from the Select Parameter
list, all you have to do is select a range of items to report, and view or print the
report. See your Reference Guide for more information on using wild card charac‐
ters.
Parameter Fields
After you select a sort key from the Sequence‐By list, you will see the parameter
maintenance screen, which will appear similar to the following illustration. Enter the data
fields as explained below to define a Production History (Detailed) Report.
Range Fields
Define the range of the sort key you selected from the Ordered‐By list, to define the
production history records that you wish to include in the report.
Line Item Detail
Select Summary, Detail, or None to select the level of detail you wish to report for each
line item in the batch.

Line Item Quantity By
Select Weight, Volume, or Alternate Unit of Measure to select the way you wish to report
the line item quantities.
Line Item Lot Numbers
Select whether or not you want the lot numbers (if any) of the formula line items printed
on the report.
Include Q/c Information
Select whether or not you want quality control test data included on the report.
Finished Goods Detail
Select Summary, Detailed, or None, to select the level of detail in which you wish finished
goods information to be printed on the report.
Finished Goods Quantity By
Select Each or Inventory to select whether you would like the finished goods quantity to
be printed on the report in terms of each, or by alternate units of measure that you have
attached to this finished good in Inventory.
Finished Goods Lot Numbers
Select whether or not you want the finished goods lot numbers (if any) printed on the
report.
Finished Goods Bill Of Materials
Select whether or not you would like the finished goods bill of materials (if any) printed
on the report.
Cost Detail
Select the level of detail for the cost information printed on the report, either Summary,
Detailed, or None.
New Page For Each Batch
Select whether or not you would like to have each batch printed on its own page.
Report Contents
The Production History (Detailed) Report lists the batch number, formula key,
description, date completed, customer key, responsibility key, weight or volume yield,
and raw material cost per unit (weight or volume). In addition, you may select to include
line‐item details, Q/C test data, finished goods details and cost details.
This report uses the Transaction Batch Master History (PNMASTH) file to report the total
material volume used/yield amounts.
Production History Report (Summary)

This option allows you to view or print a user‐defined summary of various aspects of
your production history. This report is identical to the Production History (Summary)
Report found on the Report folder.
118 Sage PFW

Production History Report (Summary)
Note: When the Cost Adjustment (E type) transaction is posted for the raw mate‐
rial, after requisitioning or closing the batch, it does not update files in produc‐
tion. Therefore Production History Report (Detailed) does not reflect the change
in the raw materialʹs cost.
Once a production batch is requisitioned or closed, no changes to the history can be made.
Therefore the Production History Report (Detailed) do not get updated with any cost
adjustment.
Procedure
Use the following procedure to generate a Production History Report:
Step Action
1 Select Production History Report from the business

desktop.

Production History Report (Summary) Window

The following is the Production History Report screen.

Sort Keys
This report can be sequenced by batch number, formula key, responsibility key, customer
key and date complete. All of these keys will appear on the parameter maintenance
screen; however, you can choose any one of them as the primary sort key. The key you
choose from the Order‐By list will appear first among the sort keys on the parameter
maintenance screen. The other keys will be secondary sort keys.
Parameter Fields
Enter the data fields as explained below to define a Production History (Summary)
Report.
Range Fields
Define the range of batch numbers, formula keys, responsibility keys, customer keys and
dates complete of the production history records that you wish to include in the report.
Report Weight Or Volume
Select Weight) or Volume) to select the terms in which you wish quantities to be reported.
Report Contents
The Production History (Summary) Report lists the batch number, formula key,
description, date complete, customer key, responsibility key, weight or volume yield, and
raw material cost per unit (weight or volume). This report uses the Transaction Batch
Master History (PNMASTH) file to report the total material volume used/yield amounts.
Raw Material Usage Report

The Raw Material Usage Report lists consumption levels for one or more raw materials
over a user‐defined range of dates. The report may be restricted to a particular item class
and/or status.
Procedure
Use the following procedure to generate a Raw Material Usage Report:
Step Action
1 Select Raw Material Usage Report from the business

desktop.

120 Sage PFW

Raw Material Usage Report
Raw Material Usage Report Window

The following is the Raw Material Usage Report screen.
Sort Keys
Data can be sequenced on the Raw Material Usage Report by the item key plus location
key.
Parameter Fields
Enter the data fields as explained below to define a report.
Range Fields
Enter the range of item keys, location keys and batch completion dates that you wish to
include in the report.
Item Class
If you wish to limit this report to one class of raw materials, select the class key, or select a
class from the lookup window. You can leave this field blank, to report all of your defined
classes. Item classes must have previously been defined in the Inventory Class
Description File Maintenance menu item.
Item Status
If you wish to limit this report to one status of raw materials, select the status key, or select
a status from the lookup window. You can leave this field blank, to report all of your
defined statuses. Item statuses must have previously been defined in the Inventory Status
file maintenance menu item.
Activity Date Range
Enter the range of dates during which these raw materials were used for which you
would like to include on this report.
Break On Location
Select Yes to print the data for each raw material location on a separate page.

Print Item Descriptions
Select Yes if you want to include the raw material descriptions in the report. Select No if
you do not want to include the item descriptions. If you have a large number of materials
to report, you may wish to select No in this field to save space and paper.
Report By Weight Or Volume
Select Weight if you wish to view the reported quantities in terms of weight, or Volume if
you prefer to view material quantities in volume units.
Select Last, Average, or Standard to select the cost method to be used on the report.
Select Active if you wish to include only active materials, Inactive for only inactive
materials, or Every Item to include every material item in the range of items and locations
specified above.
• Active means that the item was used during the specified period.
• Inactive means that the item was not used during the specified period
• Every Item means that the range of containers and locations defined above will be
reported, without regard to whether they were used or not during the activity date
range.
Report Contents
The Raw Material Usage Report displays the item key, description (if selected), location,
material cost, date‐range cost and quantity (weight or volume), average cost and quantity
per month (weight or volume), and average cost and quantity per year (weight or
volume).
122 Sage PFW

Bill-Of-Materials Listing
Listings
Description
The Production Listing options provide a handy toll for viewing or printing the
information contained in your Production data files. This allows you to uncover possible
discrepancies in data entry, view large amounts of similar data at a glance, and possibly
use the listings to establish better methods by which data is entered and maintained in the
Production application.
Listing simply gives you the information as it is stored within the data file. The
Production Listing cannot perform calculations similar to reports. If you need data
presented in a particular fashion, refer to the chapter entitled Production Reporting.
Bill-Of-Materials Listing
The Bill‐of‐Materials Listing reports bill‐of‐materials (B.O.M.) items required per finished
good in open production orders, and extended cost data regarding B.O.M. items which
have been requisitioned by virtue of a finished good being requisitioned on an open
production order. This data is sorted and retrieved from the Production Bill‐of‐Materials
(PNBOM) file.
Note: All B.O.M. items within the ranges defined will be listed, regardless of their
status. However, cost data will only appear for those items, which have been req‐
uisitioned.
Sort Keys
The Bill‐of‐Materials Listing may be sequenced by B.O.M. item key plus location key.
The Production B.O.M. data can be sequenced by only the B.O.M. item key and location.
This sequence would be used if you wanted to list only certain B.O.M. material or labor
items. For example, you could use this sequence to determine which B.O.M. items are
required for current orders. Extended cost data will be included for items requisitioned.
Listing Contents
Included in the listing are the batch number, finished good item key, finished good
location key, B.O.M. line type (item or labor), B.O.M. item key, item location key, quantity
per finished good, overhead key, total item (or labor) cost, total overhead cost and the
finished good sequence (line) number.

Finished Goods Listing

The Finished Goods Listing reports data from a user‐defined range of finished goods in
open production orders. This data is sorted and retrieved from the Production Finished
Goods (PNFINGD) file.
Sort Keys
The Finished Goods Listing may be sequenced by batch number and sequence number, by
item key and location key, or by the customer key only. Make your selection by using the
Order By drop‐down box.
You can select the range of finished goods on open production orders that you would like
to include in your listing, according to the sort key(s) you select from the Order By list.
Listing Contents
Included in the listing are the batch number, finished good sequence (line) number, item
status, item key, item location, customer key, comment, quantity ordered, quantity
produced, container key, container location, fill level, fill unit, specific gravity, inventory
unit of measure, total material cost per unit, total container and B.O.M. cost, display unit
of measure, and lot number, quarantine date, and expiration date, when applicable.
Formula Line Items Listing

The Formula Line Item Listing reports a user‐defined range of information which has
been transferred to open production orders from the Formula Line Item file. This data is
sorted and retrieved from the Production Line Item (PNITEM) file.
Note: All formula line items within the ranges defined will be listed, regardless of
their status. However, cost data and quantity used will only appear for those line
items which have been requisitioned.
Sort Keys
The Formula Line Item Listing may be sequenced by batch number and sequence (line)
number.
The range of formula line items to be listed can be defined in terms of batch numbers, and
further restricted by sequence number.
124 Sage PFW

History, Bill-Of-Materials Listing
Listing Contents
Included in the listing are the batch number, sequence (line) number, line type, line status,
item key, location key, unit or weight quantity required, unit or weight quantity used,
unit of measure, overhead key, total item (or labor) cost, and total overhead cost.
History, Bill-Of-Materials Listing

The Bill‐of‐Materials History Listing reports a user‐defined range of information about
bill‐of‐materials (BOM) items used in closed production orders. The source of this data is
the Production Bill‐of‐Materials History (PNBOMH) file.
Sort Keys
The Bill‐of‐Materials History Listing may be sequenced by the BOM item key and location
key. Make your selection by using the Order By drop‐down box.
The Production bill‐of‐materials history data can be sequenced by the B.O.M. item key
and location. This sequence would be used if you wanted to list only certain B.O.M. items.
For example, you could use the later sequence to determine how many of a particular
container have been used in your current production history.
Listing Contents
Included in the listing are the batch number, finished good item key, finished good
location key, B.O.M. line type (item or labor), item key, item location key, item quantity
units, overhead key, total item (or labor) cost, total overhead cost and the finished good
sequence (line) number.
History, Finished Goods Listing

The Finished Goods History Listing reports on a user‐defined range of finished goods in
closed production orders. The source of this data is the Production Finished Goods
History (PNFINGDH) file.
Sort Keys
There are three different sort‐key combinations that you can select for the Finished Goods
History Listing. They are batch number and sequence number, item key and location key,
or by the customer key only. Make your selection by using the Order By drop‐down box.
You can select the range of finished goods on closed production orders that you would
like to include in your listing, according to the sort key(s) you select from the Order By
list.

Listing Contents
Included in the listing are the batch number, sequence (line) number, item key, item
location, container key, container location, customer key, fill unit, final specific gravity,
comment, quantity ordered, quantity produced, fill level, and actual cost per unit of
material, container, and overhead.
History, Formula Line Items Listing

The Formula Line Items History Listing reports a user‐defined range of information from
closed production orders. The source of this data is the Production Formula Line Item
History (PNITEMH) file.
Sort Keys
The Formula Line Item History Listing may be sequenced by batch number and sequence
(line) number.
The range of formula line items to be listed can be defined in terms of batch numbers, and
further restricted by sequence number.
Listing Contents
Included in the listing are the batch number, sequence (line) number, line type, line status,
item key, item location key, overhead key, weight or alternate unit quantity required,
weight or alternate unit quantity used, unit of measure, specific gravity, actual item (or
labor) cost, actual overhead cost, and manufacturing instructions.
History, Lot Numbers Listing

The Lot Numbers History Listing reports a user‐defined range of information from closed
production orders. The source of this data is the Production Lot Number History
(PNLOTH) file. Lot numbers assigned to both batch ingredients and products will be
reported.
Sort Keys
The Lot Numbers History Listing may be sequenced by the lot number.
You will always sort your Lot Number History Listing by lot number.
126 Sage PFW

History, Production Masters Listing
Listing Contents
Included in the listing are the batch number, record type, formula key, item key, item
location, lot number, transaction date and time, quantity, customer key, vendor key,
purchase date, document number, purchase order number, receiving number, lot batch
number, bin, quarantine date, expiration date, lot status, Q/C test status, Q/C test date and
time, and lot strength factor.
History, Production Masters Listing

The Production Masters History Listing reports information from a user‐defined range of
closed production orders. The source of this data is the Production Masters History
(PNMASTH) file.
Sort Keys
The Production Masters History Listing may be sequenced by batch number
You will always sort your Production Masters History Listing by batch number.
Listing Contents
Included in the listing are the batch number, formula key, description 1 and 2, ordered
date and time, start date and time, completion date and time, fixed batch cost hours, labor
key and hourly amount, fixed batch cost overhead key and factor, overhead key and type,
variable batch cost labor key and labor amount, variable batch cost overhead factor,
overhead key and type, actual and standard material cost per unit weight, actual and
standard material specific gravity, responsibility key, customer key, and total material
volume used and yield.
History, Q/C Results Listing

The Q/C Results History Listing reports a user‐defined range of information associated
with closed production orders. The source of this data is the Production Q/C Results
History (PNQCRH) file.
Sort Keys
The Q/C Results History Listing may be sequenced by Batch Number/Sequence Number
and Formula Key/Test Description/Test Date.
You can sequence your Q/C Results History Listing by batch number or by formula key.

Listing Contents
Included in the listing are the batch number, Q/C test sequence number, formula key or
item key, Q/C test description, Q/C test type, alphanumeric target value, numeric range
low, numeric target value, numeric result, date and time tested, test status, and tested by.
History, Transactions Listing

The Transactions History Listing reports a user‐defined range of information which has
been stored in the Production Transactions History (PNTRANH) file. Each time an
inventory item is relieved from inventory, or a labor key or overhead key is charged to a
production order, an R‐type transaction is recorded. Each time a product is produced, a P‐
type transaction is recorded.
Regarding Transaction Types
Production transactions are only two types, corresponding to in and out. They are type R
(for Requisitioned), applied to a transaction where an item is used in a batch, and Type P
(for Produced), where an item is created from a batch, either an intermediate (including
bulk products) or a finished good.
Do not confuse Production transactions with inventory transactions, which have
altogether different types.
Sort Keys
The Transactions History Listing may be sequenced by batch number.
You can only sequence your Transaction History Listing by batch number. Use the Lookup
button next to the fields to make your selection.
Listing Contents
Included in the listing are the batch number, formula key, transaction type, material or
labor overhead key, location key, date, time, quantity, and comment.
Lot Numbers Listing

The Lot Number Listing reports a user‐defined range of information which has been
entered in your Production Lot Number (PNLOT) file. This data consists primarily of raw
material lot numbers, which are identified as type U (for Usage). These lot numbers were
assigned in Purchasing Pro when the material was received and transferred to the PNLOT
file when the material was committed (or requisitioned, depending on your choice in the
Production Application Setup option.
Sort Keys
The Lot Number Listing may only be sequenced by lot number.
128 Sage PFW

Production Masters Listing
You can only sequence your Lot Number History Listing by lot number.
Listing Contents
Included in the listing are the batch number, record type, formula key, item key, item
location, lot number, transaction date and time, quantity, customer key, vendor key,
purchase date, document number, purchase order number, receiving number, lot batch
number, bin, quarantine date, expiration date, lot status, Q/C test status, Q/C test date and
time, and lot strength factor.
Production Masters Listing

The Production Masters Listing reports information from a user‐defined range of open
production orders. This data is sorted and retrieved from the Production Masters
(PNMAST) file.
Sort Keys
The Production Masters Listing may be sequenced by batch number.
You will always sort your Production Masters (PNMAST) file by batch number.
Listing Contents

Included in the listing are the batch number, formula key, description, production status,
ticket (printed) flag, start date and time, ordered date and time, completion date and time,
variable cost range 1, 2 and 3, labor keys 1, 2 and 3, overhead keys 1, 2 and 3,
responsibility key, fixed cost labor key and factor (hours), overhead key, customer key,
standard material cost per unit weight, standard material specific gravity, and notes.
Q/C Results Listing

The Quality Control (Q/C) Results Listing reports a user‐defined range of Q/C test results
associated with open production orders. This data would have been entered through the
Production Daily Processing Q/C Result Maintenance option. The data for this listing is
sorted and retrieved from the Production Q/C Test Results (PNQCR) file.
Sort Keys
The Q/C Results Listing may be sequenced by batch number and test sequence number.
You will always be sorting your Q/C Results Listing by batch number

Listing Contents
Included in the listing are the batch number, Q/C test sequence number, formula key or
item key, Q/C test description, test type, alphanumeric target value, numeric range low,
numeric target, numeric range high, result type, alphanumeric result, numeric result, date
and time tested, Q/C test status, and tested by.
Responsibility Listing
The Responsibility Listing reports a user‐defined range of information which has been
entered through the Production Responsibility file maintenance menu item.
Sort Keys
The Responsibility Listing may be sequenced by responsibility key or description.
You can view or print a listing of one, a few, or all of your personnelʹs responsibility codes
and descriptions.
Listing Contents
Included in the listing are the responsibility key and description.
Scheduling Listing
The Scheduling Listing reports a user‐defined range of information which has been
entered through the Production Scheduling option, or the MRP Scheduling option, if you
have installed Material Requirements Planning (MRP) application. This data is sorted and
retrieved from the Production Scheduling (PNSCHED) file.
Sort Keys
The Production Scheduling Listing may be sequenced by formula key.
You can only sequence the data from your Production Schedule file by formula key.
Listing Contents
Included in the listing are the formula key, item key, item location, order quantity, start
date and time, finish date and time, customer key (if the schedule record was based on a
customer order), comment, and record status.
130 Sage PFW

Appendix A:
Production Data Files

Appendix A:
Introduction
This section provides important additional information about the data files compatible
with the Production application.
In this chapter
Topic Page
Data File List and Descriptions 132

Data File List and Descriptions
Description
The following data files are used to store records of your production orders, production
transactions and production history.
Production Master File

The Production Master (PNMAST) file contains the basic information about your current
production orders, and is the source of information about your work in process. This data
includes each batch number, formula key and description, responsibility key, batch status,
ticket printed status, notes, date and time order entered, date and time to start, date and
time to finish, customer key, labor cost keys for fixed and variable labor costs per batch,
overhead keys for overhead costs attached to fixed and variable labor costs, and specific
gravity override.
Production Finished Goods File

The Production Finished Goods (PNFINGD) file contains data that was entered on the
Finished Goods Screen of the Batch Entry option (or by automatic scheduling). This data
includes the batch number, sequence number, item status, item key, location key,
customer key, comment, weight or unit quantity ordered, weight or unit quantity
produced, container key (defaulted), container location, fill level (defaults to finished
good fill level), fill unit (weight or volume), inventory unit of measure, material cost,
container plus BOM cost, labor cost, overhead cost, display unit of measure, optional lot
number, quarantine date and expiration date, and sales order number (when scheduled
from a customer order).
Production Formula Line Item File

The Production Formula Line Item (PNITEM) file contains the formula ingredients and
other line‐item data that was acquired from your master formula when the batch was
created. This data includes the batch number, sequence (line) number, line type, line
status, item key, item location (optional), date and time to start, date and time to finish,
quantity required (weight or units, if labor), quantity used (weight or units, if labor), use
weight, volume or alternate unit of measure, overhead key (optional), boilerplate
paragraph key or literal manufacturing instruction, actual final total material, labor, and
overhead costs including those from the itemʹs bill‐of‐materials (determined when a line
item is requisitioned).
Production Lot Number File

The Production Lot Number (PNLOT) file contains primarily the raw material lot
numbers for ingredients which require lot‐tracking, and were requisitioned in a
production batch. This data includes the batch number, lot type, formula key, item key,
location key, lot number, date and time of transaction, quantity, customer key, and
additional information about purchased items (vendor, purchase date, purchase order
number, receiving and Q/C test data, etc.)
132 Sage PFW

Regarding Types of Production Lot Records

If you select, in the Production Application Setup file maintenance menu item, to have lot
Appendix A:
numbers assigned when materials are committed to production, instead of when they are
requisitioned, those records will be identified in this file as type C (for Committed),
instead of type U (for Usage), which represents lots assigned at material requisition.
Type P (for Production) lot numbers only appear in the PNLOT file when you use the
Daily Processing Close W/O Transfer option. These lot numbers are those which you
assign to finished goods (or intermediates) that you produce in Production.
Normally, type P lot numbers are assigned when you close an order, so they go directly to
the Inventory In‐Stock Lot Number file and the Production Lot Number History file.
Production Q/C Result File

The Production Quality Control (Q/C) Result (PNQCR) file contains the data that your
inspectors enter (or record on the printed batch ticket) after testing a batch sample. This
data includes the batch number, test sequence number, formula key, Q/C test description,
target type, target value (plus high and low limits, if type is numerical), Q/C test results,
date and time tested, test status, and tested by.
Production Bill of Materials File

The Production Bill of Materials (PNBOM) file contains the bill‐of‐materials (BOM) items
and labor which are attached to a finished good which has been requisitioned on a current
production order. This data includes the batch number, finished good item key, location
key, BOM line type (I for item or L for labor), BOM item key, location key, quantity,
overhead key, the total item or labor cost requisitioned so far, the total overhead cost
requisitioned so far, and the finished good sequence (line) number.
Production Responsibility File

The Production Responsibility (PNRESPON) file contains the responsibility key and
description. This key is entered in Batch Entry to identify the person responsible for
creating the production order.
Production Scheduling File

The Production Scheduling (PNSCHED) file contains records which include all the
information necessary for you to convert the schedule record to a production order. This
data includes the formula key, item key, location key, quantity ordered, date and time to
start, date and time to finish, customer key (if schedule resulted from a customer order),
comment, record status, order number (if schedule record resulted from a customer
order), production line (optional), fill line (optional), record type, and whether to exclude
this record from the master production schedule (MPS) (this field is used by Material
Requirements Planning (MRP)).
Production Configuration File

The Production Configuration (PNONE) file contains Production application defaults,
including the next batch number, type of production history tracking, the default batch
ticket layout, plus lot‐tracking options and last system document identification.

Formula Overhead File
The Formula Overhead (FMOVERHD) file contains the overhead key, description, type,
which is either dollar amount ($) or percentage (%), the numerical factor, and general
ledger account numbers for control, variance and offset accounts.
Formula Labor/Additional Cost File

The Formula Labor/Additional Cost (FMADDCOST) file contains the labor/additional
cost keys, description 1 and 2, type (L for labor or O for other), cost amount, and general
ledger account numbers for control, variance and offset accounts.
Batch Master History File

The Batch Master History (PNMASTH) file is similar to the Production Master file, but
also includes production cost data that was calculated when the order was closed. This
data includes labor cost keys and factors for fixed and variable labor cost per batch,
overhead keys and factors for overhead costs associated with fixed and variable labor, and
comparable values from the batch and the master formula, such as actual batch weight
raw material cost (RMC) per unit weight, standard weight RMC per unit weight, actual
specific gravity and master formula specific gravity, plus the total material weight used,
total material weight yield, total material used by volume and total material yield by
volume.
Batch Finished Goods History File

The Batch Finished Goods History (PNFINGDH) file is similar to the Finished Goods file,
but also contains the final specific gravity, and does not include the production lot number
data, which was transferred to the Batch Lot History file when the order was closed.
Batch Line Item History File

The Batch Formula Line Item History (PNITEMH) file is similar to the Line Item file, but
contains the final cost data and specific gravity (for material line items).
Batch Lot History File

The Batch Lot History (PNLOTH) file contains both raw material lot number data that
was entered in the Production Lot Number file when materials were requisitioned, and
production lot numbers that were assigned to products during production.
Batch Q/C Result History File

The Batch Q/C Result History (PNQCRH) file contains the data that was entered in the
PNQCR file, before the batch was closed.
Transaction History File

The Transaction History (PNTRANH) file contains a record of each raw material that was
requisitioned, and each item produced, for every closed batch This data includes the
batch number, formula key, transaction type (R for requisitioned items, P for production
items), item key, location key, date, time, quantity and comment.
134 Sage PFW

Index
Index
A generating, 88
Batch in Process Report, 88
Batch in Process Report Window, 89
Activating Production Orders, 60 Batch Line Item History File, 134
Actual Completion Date Batch Lot Number File, 134
Batch Entry, 44 Batch Master History File, 134
Actual Completion Time Batch Number and Formula Key
Batch Entry, 46 Batch Entry, 43
Actual Start Date Batch Q/C Result History File, 134
Batch Entry, 44 Batch Sizing, 4
Actual Start Time Batch Status, 5
Batch Entry, 46 Batch Ticket, 7
Adjusting Finished Goods Bill of Materials Quantities Batch Ticket Boilerplate
Button, 51 Field Description, 26
After Section n How to Complete, 26
Batch Ticket Boilerplate, 26 Batch Ticket Boilerplate window, 26
Alternate Unit Format Batch Ticket Boilerplates, 25
Batch Ticket Layout, 30 Batch Ticket Layout, 27
Application Setup, 15 Field Description, 28
description, 15 How to Complete, 28
field descriptions, 16 Batch Ticket Layout window, 28
how to complete, 16 Batch Type
tabs, 16 Batch Entry, 46
window, 15 Batch Weight/batch Volume
Assign Batch Number To Completed Lots Batch Entry, 44
Lot Tracking Configuration, 25 Bill‐Of‐Materials Listing, 123
Assign lots during commit Boilerplate /literal Text On
Application Setup, 18 Batch Ticket Layout, 29
Assigning Lot Numbers for Raw Material Usage, 61 By‐Product Costing, 9
Automatic Posting of Production Transactions, 62 By‐Products Tab, 53
Automatically Assign Lots
Lot Tracking Configuration, 24
Availability of One Material, 51
C
Available Materials, 51
Calculate Lot Expiration Date
B Lot Tracking Configuration, 25
Canceling Production Orders, 63
Changing the Status of a Batch, 59
Base labor and overhead on usage/yield Closing Batches, 66
Application Setup, 18 Closing Production Orders, 64
Batch Edit Report Column Width
contents, 66 Batch Ticket Boilerplate, 27
generating, 65 Comment
print in Batch Entry, 45 Batch Entry, 48
printing, 64 Committed Batch Report, 89
window, 65 Committed Batch report
Batch Entry Fields ‐ Batch Tab, 43 generating, 90
Batch Finished Goods History File, 134 Committed Batch Report Window, 90
Batch In Process Committing Production Orders, 60
Report Contents, 89 Container Usage Report, 91
Batch in Process

D-H
generating, 91 F
Container Usage Report Window, 92
Container Where Used in Process
generating, 94 Fill From Inventory?, 81
Container Where Used in Process Report, 94 Finished Good Lot Explosion Report, 96
Window, 94 generating, 97
Correcting the Schedule, 76 Finished Good Lot Explosion Report Window, 97
Costs Tab, 46 Finished Goods In Process Report, 98
Creating Batches for Intermediates and Bulk Products Finished Goods in Process Report
(The One‐Step Method), 81 generating, 98
Creating Batches From the Schedule, 80 Window, 99
Creating Separate ʺMaterials Onlyʺ and ʺFillʺ Orders Finished Goods Listing, 124
(The Two‐Step Method), 80 Finished Goods Ordered*, 50
Creating/Updating Production Orders, 41 Finished Goods Production Report, 99
Critical Materials Report, 95 generating, 100
generating, 95 Window, 100
Critical Materials Report Window, 96 Finished Goods tab, 47
Customer Formula
Batch Entry, 48 Scheduling Formula, 35
Customer Key Formula Key
Batch Entry, 43 Scheduling Formula, 34
Formula Labor/Additional Cost File, 134
Formula Line Items Listing, 124
Formula Overhead File, 134
D
Formula Production Report, 101
generating, 102
Decimal places Formula Production Report Window, 102
Application Setup, 18 Formula Statuses Not Allowed in Production, 8
Decimal Places Tab, 18 Formula statuses not allowed in production
Density Override Application Setup, 17
Batch Entry, 45 Formula Tab, 52
Description
Responsibility, 37
Scheduling Formula, 35 G
Description 1‐2
Batch Entry, 43
Display standard / average / last cost Generate Schedule Window, 72
Application Setup, 18 Generating a Schedule, 71
Generating a Schedule Report, 74
E
H
Edit Report Status
Batch Entry, 44 History tracking
Entering Production Orders Application Setup, 17
methods, 40 History, Bill‐Of‐Materials Listing, 125
Estimate Run Time History, Finished Goods Listing, 125
Batch Entry, 46 History, Formula Line Items Listing, 126
Expiration Date History, Lot Numbers Listing, 126
Batch Entry, 49 History, Production Masters Listing, 127
Expression 1 History, Q/C Results Listing, 127
Scheduling Formula, 35 History, Transactions Listing, 128
Expression 2
Scheduling Formula, 35
136 Sage PFW

I-P
I Field Descriptions, 23
How to Complete, 23
Lot Tracking Configuration window, 23
Identifying Material Shortages, 53 Lot, Bin, SSCC
Include Bills‐of‐materials Batch Entry, 49
Index
Batch Ticket Layout, 32 Lot/Bin/SSCC Sheet
Include Finished Good BOMS Labor Info. Batch Entry, 49
Batch Ticket Layout, 32
Include Finished Good Info On
M
Include Q/C Specifications On
Inquiring an Existing Production Order, 41 Material Lot Number Explosion Report, 108
Inventory generating, 108
interface, 11 Window, 109
Inventory Statuses Not Allowed in Production, 8 Material Variance Report, 110
Inventory statuses not allowed in production generating, 110
Application Setup, 17 Material Variance Report Window, 111
Inventory Usage and Cost Data, 5 Material Where Used In Process Report, 112
Item Key Material Where Used in Process Report
Batch Entry, 47 generating, 112
Material Where Used in Process Report Window, 112
Maximums
L Application Setup, 18
Maximums Tab, 18
Method 1 ‐ Manual Entry
Line Items Sheet Entering Production Orders, 40
Batch Entry, 47 Method 2 ‐ Automated Production Scheduling
Listing Entering Production Orders, 40
Bill‐of‐Materials, 123 Miscellaneous Tab, 45
Finished Goods, 124 MSDS
Finished Goods History, 125 interface, 11
Formula Line Item, 124
Formula Line Items History, 126
Lot Number, 128
N
Lot Numbers History, 126
Production Masters, 129
Production Masters History, 127 Next batch number
Q/C Results History, 127 Application Setup, 16
Quality Control (Q/C) Results, 129 Note 1 ‐ 4
Responsibility, 130 Batch Entry, 46
Scheduling, 130
Transactions History, 128
Listings, 123 O
Location
Batch Entry, 48
Logic Operator Order Printed
Scheduling Formula, 35 Batch Entry, 45
Lot Numbers Listing, 128 Order Time
Lot Recall Report, 103 Batch Entry, 45
Data file usage, 104 Order Weight/order Volume
Setup Requirements, 104 Batch Entry, 44
Lot Statuses Allowed In Production
Lot Strength Factor, 8 P
Lot Tracking, 5
Lot Tracking Configuration, 22 Partially Closing Batches, 67

Q-S
Placing Production Orders on Hold, 60 Q
Preface, 1
Premix Quantity*, 50
Print Batch Ticket, 54 Q/C Results Listing, 129
Print Batch Tickets Q/C Results Tab, 53
How to, 54 Qty Ordered
Print Pick List, 113 Batch Entry, 48
generating, 113 Qty Produced
Print Pick List Window, 114 Batch Entry, 48
Printing a Batch Edit Report, 45, 64 Qty Required
Printing a batch ticket, 45 Batch Entry, 52
Process Cell Qty Used
Batch Entry, 46 Batch Entry, 52
Production Quality Control, 5
features, 4 Quantity of One Material, 51
Production Bill of Materials File, 133 Quarantine Date
Production Configuration File, 133 Batch Entry, 49
Production Cost Summary Report, 115
generating, 115
Production Cost Summary Report Window, 115 R
Production Data Files, 131
Production Finished Goods File, 132 Raw Material Usage Report, 120
Production Formula Line Item File, 132 generating, 120
Production History, 5 Window, 121
Production History Report (Detailed), 116 Regarding Quick‐Step Batch Ticket Production, 67
generating, 116 Require Expiration Date
Window, 117 Lot Tracking Configuration, 24
Production History Report (Summary), 118 Require Lot Status
generating, 119 Lot Tracking Configuration, 24
Window, 119 Require Passed Q/C Status
Production Lot Number File, 132 Lot Tracking Configuration, 24
Production Lot Numbers, 7 Require Quarantine Date
Production Master File, 132 Lot Tracking Configuration, 23
Production Master Listing Requisitioning Production Orders, 61
How to, 57 Responsibilities, 36
Printing, 57 Responsibility
Production Masters Listing, 129 Batch Entry, 43
Production Order Date Field Descriptions, 37
Batch Entry, 43 How to Complete, 36
Production Order Notes Through Line Responsibility Key
Batch Ticket Layout, 29 Responsibility, 37
Production Order Status, 9 Responsibility Listing, 130
Production Orders Responsibility window, 36
How to Enter, 41 Restricting Formulas and Materials, 8
Production Q/C Result File, 133
Production Responsibility File, 133
Production Scheduling File, 133 S
Production Status
Batch Entry, 44
Purge Forecast Records, 86 Schedule Report Window, 74
Purge Schedule Records Window, 85 Scheduled Completion Date
Purging Schedule Records, 85 Batch Entry, 44
generating, 85 Scheduled Completion Time
Batch Entry, 46
Scheduled Start Date
Batch Entry, 43
Scheduled Start Time
138 Sage PFW

T-W
Batch Entry, 45 Volume*, 50
Scheduling, 5, 33
Scheduling Both Materials and Finished Goods, 80
Scheduling Finished Goods Only (The Half Step), 82 W
Scheduling Formula
Index
Field Descriptions, 34
How to Complete, 34 Weight Column Format
Scheduling Formula window, 34 Batch Ticket Layout, 29
Scheduling Listing, 130 Weight*, 50
Scheduling Production, 71
Sequence Lots By
Setup Costs
Batch Entry, 47
Sizing a Batch Button, 50
Special Features
Batch Entry, 50
Special Features in Batch Entry, 45
Status
Batch Entry, 47
Toggling the Unit of Measure Button, 52
Transaction History File, 134
Transfer blank Q/C results to history
Application Setup, 17
Transfer Q/C targets to results
Uncommiting Production Orders, 61
Unit
Batch Entry, 48
Update finished good on hand before close
Use Rounding For Alternate Unit Quantities
Use Rounding For Labor Quantities
Use Rounding For Volume Quantities
Use Rounding For Weight Quantities
Useful Reports, 6
Variance, 9
Volume Column Format

W-W
140 Sage PFW

Production Guide

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Production Guide

Uploaded by

Copyright:

Available Formats

Production User Guide

Chapter 1: Introducing Production

Chapter 2: Setting Up Production

Chapter 3: Using Production

Production User Guide i

Chapter 4: Generating Reports and Listings

Appendix A: Production Data Files

Production User Guide iii

About this user guide

Document Name Description

Production User Guide 1

Document Name Description

Production User Guide 3

Inventory Usage and Cost Data

Production User Guide 5

Concepts You Need to Know

Production Lot Numbers

Production User Guide 7

Lot Strength Factor

Restricting Formulas and Materials

Formula Statuses Not Allowed in Production

Inventory Statuses Not Allowed in Production

Production Order Status

Production Order Status

Production User Guide 9

Production and Other Applications

Order Entry Pro

Production User Guide 11

Production User Guide 13

Setting up System Setup Files

Application Setup window

Production User Guide 15

How to Complete the Application Setup Window

1 Select Application Setup from the business desktop.

Description of Application Setup Options - Application Setup Tab

Next batch number

Track production history

Transfer blank Q/C results to history

Inventory statuses not allowed in production

Formula statuses not allowed in production

Transfer Q/C targets to results

Production User Guide 17

Assign lots during commit

Display standard / average / last cost

Base labor and overhead on usage/yield

Update finished good on hand before close

Decimal Places Tab

Edit Report Tab

Require Edit Report before Batch Close

Verify Non-Lot Tracked Critical Materials

Verify Loss Constant per Batch Weight

Production User Guide 19

Verify Loss Factor

Variance between Batch Weight and Order Weight

Variance between Quantity Ordered and Produced

Quantity Produced is Zero

BOM Quantity Differs from Inventory BOM

Finished Good Formula differs from Batch Formula

Variance between Quantity Required and Used

Verify Loss Factor

Production User Guide 21

Finished Goods with BOM’s used as Raw Materials

Setting Up Lot Tracking Configuration

Lot Tracking Configuration window