Understanding Work Orders
This guide explains what Work Orders are and how they fit into your manufacturing process. Whether you're a production manager or a shop floor operator, this guide will help you keep track of your work.
What is a Work Order?
Think of a Manufacturing Order as a complete recipe (e.g., "Bake a Cake"). A Work Order is a single step in that recipe (e.g., "Mix Ingredients", "Bake in Oven", "Decorate").
When you confirm a Manufacturing Order, the system breaks it down into individual Work Orders. Each Work Order represents a specific operation that needs to be done at a specific Work Center.
Why does this matter?
- Granular Control: Track progress step-by-step.
- Resource Management: Schedule specific machines or stations (Work Centers).
- Cost Accuracy: Track the actual time spent on each operation to calculate labor and overhead costs precisely.
Relationship to Manufacturing Orders
A Manufacturing Order (MO) is the parent document. It tells you what to make and when. The Work Orders (WO) are the children; they tell you how to make it, step by step.
graph TD
MO[Manufacturing Order: 100x Tables] --> WO1[WO #1: Cut Wood]
MO --> WO2[WO #2: Assemble Legs]
MO --> WO3[WO #3: Varnish]
style MO fill:#f9f,stroke:#333
style WO1 fill:#bbf,stroke:#333
style WO2 fill:#bbf,stroke:#333
style WO3 fill:#bbf,stroke:#333
- One Manufacturing Order generates Multiple Work Orders.
- You must typically complete Work Orders in sequence (Step 1 → Step 2 → Step 3).
Work Order Lifecycle
A Work Order goes through a specific lifecycle as it moves through your shop floor:
Pending ──▶ Ready ──▶ In Progress ──▶ Done
⏳ ✅ ⚙️ 🎉
⏳ Pending
- The Work Order is created but cannot start yet.
- Usually waits for a previous step to finish (e.g., you can't "Varnish" before you "Assemble").
✅ Ready
- All prerequisites are met.
- Raw materials are available (if applicable).
- The Work Center is ready to take this job.
⚙️ In Progress
- Work has started.
- The timer is running (tracking actual duration).
- Components are being consumed.
🎉 Done
- The operation is complete.
- The output is ready for the next step or final storage.
- Actual costs are recorded.
[!NOTE] You can also Cancel a Work Order if the Manufacturing Order is cancelled or if the production plan changes.
Assigning to Work Centers
Every Work Order is assigned to a Work Center. This is the specific location or machine where the work happens (e.g., "Assembly Line 1", "Drill Press A").
- Capacity Planning: The system schedules Work Orders based on the Work Center's availability.
- Costing: The cost of the Work Order is often calculated based on the Work Center's hourly rate.
[!TIP] See the Understanding Work Centers guide for more details on configuring your stations.
Time Tracking
Accuracy is key for costing. Each Work Order tracks two types of time:
| Time Type | Description | Why it matters |
|---|---|---|
| Planned Duration | How long we think it will take. From the Bill of Materials. | Used for scheduling and estimated costs. |
| Actual Duration | How long it actually took. Recorded by the operator. | Used for actual costing and efficiency reporting. |
How to track time:
- Click Start when you begin the work.
- Click Pause if you take a break or shift ends.
- Click Done when the task is finished.
The system will automatically calculate the Actual Duration.
Component Consumption
Some Work Orders consume specific components. For example, the "Assembly" step might consume "Screws" and "Wood Panels".
- Manual Consumption: You record exactly what you used.
- Backflushing: The system automatically "consumes" the expected amount when you click Done.
Ensure you record consumption accurately to keep your inventory levels correct.
Best Practices
📅 Sequence Matters
- Follow the sequence defined in the Manufacturing Order. Skipping steps can lead to quality issues or confusion.
⏱️ Be Honest with Time
- Record actual start and stop times. If a job takes longer, we need to know why (machine breakdown? bad materials?) to improve future planning.
🧹 Keep Work Centers Clear
- Mark a Work Order as "Done" only when the physical items have moved to the next station. This keeps the schedule accurate.
Troubleshooting
Q: Why is my Work Order stuck in "Pending"?
A: This usually means the previous step hasn't finished yet. Check the Manufacturing Order to see the status of preceding Work Orders.
Q: Can I change the assigned Work Center?
A: Yes, if the Work Order hasn't started yet. This is useful for load balancing if one machine is busy.
Q: Why is my "Actual Cost" higher than expected?
A: Check the Actual Duration. Did the operator forget to stop the timer? Or did the machine run slower than the Planned Duration?