All functionality discussed below is available both in Sage 200 and in the Sage 50 ‘Manufacturing Controller’, ‘Job Controller’ (1-off type only) and ‘Batch Controller’ (Batch type only) variants.

There are 3 ways to create Works Orders in Sage Manufacturing. The recommended and most widely used method is via MRP, which automatically creates Works Orders when recommendations are actioned. In addition, Works Orders may be generated directly from the Trial Kitting facility in Bill of Materials or created manually within the Works Order Processing module.

However created, Works Orders may be amended during processing. Raw materials/components and manufacturing operations etc. can be added or removed.

On the Works Orders ‘List’ display, any items which are predicted to be late are displayed in red. The main steps for processing a Works Order are:

Allocate > Print Documents > Issue> Enter Costs(optional)> Complete*

*Sage 200 has a further step – ‘Close’. See differences section.

Allocation sets aside stock to be used against a Works Order thereby preventing it being used for any other purpose by the system. There is no overall effect on stock quantities or values, Free Stock is reduced and Allocated Stock increased. Note that negative stocks should never be used in conjunction with Sage Manufacturing. Allocations can be partial and can be manually amended or completely reversed should the need arise.

There are 4 standard documents which may be printed out, although 3 of them show virtually the same information in different formats. The Picking List shows details of the components required for each job, along with details of locations, batch numbers (Sage 50/Sage 200) and/or serial numbers (Sage 200 only).

The Route Card (or Traveller), Operation Card and Job Sheet all show Operations in varying degrees of detail. All layouts can be amended - this is best carried out by your Sage Manufacturing Accredited Business Partner.

Issuing stock against a Works Order reduces Allocated Stock and updates the Works Order record with the material cost depending on the cost basis. The value of issued stock will now show on Work In Progress reports, and may optionally be updated into the Nominal Ledger. Issues can be partial and can be manually amended or completely reversed should the need arise.

Actual Labour costs may be entered manually or using the Shop Floor Data Collection module (included in Sage 200 but priced separately for Sage 50)

Manual entries for operation times may be made from employee timesheets or directly from the Route Card.

Completing a Works Order increases the Free Stock of the finished item which no longer shows as Work In Progress. There are significant differences in the treatment of costs between Sage 50 and Sage 200 – please see the section below. Issues can be partial but once made are irreversible. Adjustments after completion need to be made directly in Stock Control or via the Scrap Finished Item routine.

The 'Create/Update' button offers 3 options:

1. Any amendments made to the Works Order during processing e.g. to components/raw materials or manufacturing operations, can be made permanent either by updating the existing BOM or creating a new BOM.
2. A ‘one-off’ job can be converted to a BOM, but note that ‘non-stock’ and ‘other expense’ items are lost. Non-stock items should be converted to stock items before this routine is run.
3. An Estimate can be created from a ‘one-off’ type Works Order - useful for when an Estimate needs to be provided for a job similar to one already carried out.

Next: Differences between Sage 200 and Sage 50 Works Order Processing