modules
Manufacturing
Stop building the wrong revision — every order locked to released engineering.
The most expensive words on a shop floor are 'which revision are you building?' Wrong components ordered, capacity scheduled against obsolete routings, dates promised the new design cannot meet. Manufacturing ends that: one object family from release through close, so the BOM on the work order is the version engineering released and the costs are the ones finance will actually book.
Why manufacturing truth matters
Engineering releases a BOM change and manufacturing finds out weeks later — after buying the wrong components, scheduling against obsolete routings, and promising dates the new design cannot meet. XRP keeps one object family from release through close: the BOM version on the work order is the version engineering released, the routing is the one capacity planned against, and the costs are the ones finance will actually book. Work orders carry BOM snapshot, routing, operations, quality checks, labor, material moves, and cost accumulation in one object. Phantom items explode transparently, matrix BOMs resolve configurations without part-number sprawl, and contract manufacturing tracks vendor operations with the same rigor as internal ones.
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section: thesis
Who answers for Manufacturing
Four roles, four anxieties, one object family answering each.
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section: personas
Section 1
col Title: COO
col Cont: Throughput without the revision roulette. Capacity plans against released engineering, lines run released routings, and delivery commitments update the moment a revision lands — instead of after the wrong parts arrive.
Section 2
col Title: Plant Manager
col Cont: Work orders, BOMs, routing, costing, quality, and capacity in one object. When a machine goes down, the blast radius across production, supply, and commitments is visible immediately — not at the next meeting.
Section 3
col Title: Quality Leader
col Cont: Checks, NCRs, and corrective actions bound to the exact lot, operation, and operator. Recalls scope in one query instead of a week of spreadsheets.
Section 4
col Title: CFO
col Cont: Job costs complete at work-order close with standard-to-actual variance already calculated. No month-end reconstruction of what the floor really spent.
Manufacturing capabilities
- Revision-locked orders
- Work orders bind released BOM and routing snapshots with full state history
- Practical shop flows
- Dependency-aware operations, time capture, scrap, rework, split/merge, by-products
- Genealogy built in
- Serial and lot traceability from receipt through production to shipment
- Quality inline
- Checks, FMEA linkage, and yield analytics on the operation, not in a side system
- OEE live
- Availability, performance, and quality feed BI as events validate
- Cost with close
- Completion posts costs to finance and updates inventory in one transaction
- section
- capabilities
From revision chaos to one truth
subtitle: What each stage feels like after adoption.
layout: alternating
enable Slideshow: false
slideshow Interval: 5000
Orders lock to released engineering
date: Phase 1
status: in-progress
BOM and routing snapshots pin per order; wrong-revision builds stop immediately.
has Learn More: false
Planning replans on change
date: Phase 2
status: upcoming
Engineering releases propagate to MRP, capacity, and commitments the same hour.
has Learn More: false
Costs complete at close
date: Phase 3
status: upcoming
Job costs land with the work order instead of being reconstructed at month-end.
has Learn More: false
Recalls answer in one query
date: Phase 4
status: upcoming
Genealogy from receipt through production scopes any recall in seconds.
has Learn More: false
Manufacturing in daily operation
Each surface below works the same order object — planning explodes it, the floor executes it, vendors extend it, and scanners prove every move.
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section: applications
Contract Manufacturing
Vendor operations tracked like internal ones: material shipments to vendors, outside processing steps, finished-goods receipts, and cost reconciliation — with vendor identity and evidence on every outside step.
Phantom and Matrix BOMs
Phantom items flatten transparently during MRP while matrix BOMs resolve configurations without part-number sprawl. Substitutions carry effectivity and approval so the floor never guesses which revision applies.
Barcode Scanning
Composite scanning validates item, lot, serial, and operation in one pass. Wrong-lot and wrong-operation scans refuse with the correct target directed, and every scan writes genealogy into the unit record.
Advanced Operations
Rework loops, split and merge, by-products, tooling checks, setup matrices, and digital-twin state ride the routing as governed steps — not tribal knowledge kept in supervisors' heads.
Bin Management
Floor-stock bins with full CRUD: create, move, count, and consume with lot constraints enforced. Line-side inventory stays accurate without freezing production for counts.
Manufacturing sub-modules
subtitle: Plan feasibly, execute completely.
data View: manufacturing:sub-modules
MRP Planning
desc: Material plans from live facts.
link: /sub-modules/mrp-planning
Shop Floor
desc: Work orders with everything attached.
link: /sub-modules/shop-floor
Manufacturing questions
Section 1
Who owns manufacturing truth here versus finance and warehouse?
Manufacturing owns BOM, routing, and work-order execution. Finance owns posting truth; Part 10 owns stock truth. Boundaries are enforced by owner gates, not duplicated records.
Section 2
How are engineering changes absorbed mid-production?
Open orders keep their released snapshots; new orders take the revision. Effectivity dates govern the cutover, and impacted plans replan with the change cited.
Section 3
What about contract manufacturers?
Vendor operations track with the same structure — operations, materials, quality, and costs — with vendor identity and evidence attached to every outside step.
Section 4
Where does OEE come from?
Availability from downtime records, performance from operation times versus standards, quality from check results — all validated events, computed live.
Section 5
Our engineers change designs constantly. Won't versioning drown us?
Effectivity dates do the drowning for you: open orders stay pinned while new orders take the revision. The system absorbs churn that today lives in expediters' heads.
Section 6
Will operators actually use shop-floor terminals?
They already capture time, quantities, and scrap to keep lines moving — the terminal just stops the paper transcription afterward. Barcode validation makes the right scan faster than the wrong one.
Section 7
We just bought an MES. Is it wasted?
Its data migrates with lineage and its integrations map through proof-gated profiles. What the MES did well becomes evidence in the new core instead of sunk cost.
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section: faqs
content section
value: An engineering change releases once and propagates everywhere: planning, orders, costing, and delivery commitments update together. MRP replans against real inventory and real capacity the moment the revision lands.
Section 9
Versioned BOMs with effectivity dates, variants, and substitution rules
Section 10
Phantom items, matrix BOMs, and pegged supply for configurable products
Section 11
Capacity-aware MRP with instant replan on engineering change
Section 12
Shop-floor execution with time capture, dependencies, and split/merge
Section 13
Quality checks, scrap, rework, and yield analytics inline
Section 14
Serial and lot genealogy from component to finished unit
Section 15
OEE and downtime tracking feeding BI without batch delay
Section 16
Live cost accumulation into finance on every close