[Enhancement] Work Order Material Consumption by creamdory · Pull Request #13384 · frappe/erpnext

creamdory · 2018-03-24T09:32:06Z

Made the enhancements from these issues:

#13368
#13369
#13368

BOM:

Usecases:

Usecase:

1 transfer, 1 consumption and 1 Finish from a Work Order

Work Order

Material Transfer

Material Consumption

Work Order Completion

Usecase:

Multiple Transfer, Consumption and Finish from a Work Order.

Work Order
Partial Stock Transfer suggest only "Required Qty" * "Qty for Material Transfer for Manufacture". If we click "Finish" before any "Material Consumption", must suggest Qty to consumed in the Manufacture Stock Entry. If we create "Material Consumption for Manufacture" before "Finish", must take into account the "Consumed Qty" during Finish.

Usecase:

Work Order with Partial transfer, consumption and completion.

Material Transfer : Suggest the total Stock to be transferred from the "Required Qty" column and the "Qty for Material Transfer for Manufacture".

Material Consumption : Suggest and allow only consumption less than or equal to the "Transferred Qty".

Finish Production : Suggest consumption of materials less than the "Consumed Qty" and base total consumption qty from the "Qty for Manufacture".

Validations

Doesn't allow consumption more than Transferred Qty.

Allow Transfer more than the Required Qty. Allow Consumption more than required Qty.
Doesn't allow cancellation of "Material Consumption for Manufacture" when Work Order is Completed.

Notes

Please help test, write feedbacks and report issues.
Test Case Creation is on going.
Documentation will be after Alternative BOM line and Work Order renaming Documentation is done.

dottenbr · 2018-03-24T20:12:33Z

Let me quickly explain why we didn’t yet contribute documentation on this.

We have not updated the documentation since the Frappe team is working on that currently due to the Production Order to Work Order transition. Whoever works on that could include this in the documentation if the design gets accepted or we can contribute the documentation after the updated documentation is available.

dottenbr · 2018-03-25T20:16:03Z

Could you let us know if there is anything you need from us to get the PR merged ASAP? We are on a tight schedule. We are migrating on Friday this week and need this in.

creamdory · 2018-03-26T09:03:33Z

@nabinhait we bumped into an issue with this design since it records "issuance" accounting in the new purpose "Material Consumption for Manufacture". This creates a problem in making/calculating Valuation Rate of the Finish product.

Can you suggest how to proceed so we can change code right away? Issue was pointed out in this discuss post https://discuss.erpnext.com/t/material-consumption-for-manufacture/35076.

creamdory · 2018-03-26T10:11:49Z

@nabinhait , here is my suggestion. We should have the idea of recording "WIP" accounts.

So in the current design, we have these accounting entries for direct material:

"Manufacture" Stock Entry:

DEBIT: Finish Goods $ 1.00
CREDIT: Components $ 1.00

If we will be adding the idea of "Material Consumption for Manufacture", we can have these accounting entries:

"Material Consumption for Manufacture" Stock Entry:

DEBIT: WIP Direct Material $ 1.00
CREDIT: Components $ 1.00

"Manufacture" Stock Entry:

DEBIT: Finish Goods $ 1.00
CREDIT: WIP Direct Material $ 1.00

OR

"Manufacture" Stock Entry:

DEBIT: Finish Goods $ 1.00
CREDIT: WIP Direct Material $ 0.50
Components $ 0.50

So the components will be exhausted during the consumption using a WIP account. This means that we need to allow the "Manufacture" stock entry to record the "WIP" cost and use this to calculate the finish good's valuation rate. The WIP accounts should also show in the Balance sheet. We can add a column/field in the "Company" doctype as "WIP Direct Material" account to set-up the default account for this scenario. Same is true with Direct Material.

Let us know what you think.

djpalshikar · 2018-03-26T10:24:56Z

Doesn't allow consumption more than Transferred Qty.

Currently if the WIP warehouse has enough stock, "Finishing is allowed", is there is specific reason why you would like to disallow consumption ?

We should have the idea of recording "WIP" accounts.

Can you should how the stock ledger will look like after consumption and completion?

creamdory · 2018-03-26T10:32:53Z

@djpalshikar can you pls put feedback from my recent suggestion about WIP accounts?

creamdory · 2018-03-26T10:48:25Z

@djpalshikar

Currently if the WIP warehouse enough stock, "Finishing is allowed", is there is specific reason why you would like to disallow consumption ?

This is the idea. If the WIP has enough stock it can consume. But if WIP only has 50 and consumption is 60 then this is not allowed.

We should have the idea of recording "WIP" accounts.

In my recent comment, you can look at the accounting entries. For the Stock Ledger, here it is:

"Material Consumption for Manufacture" Stock Entry

"Manufacture" Stock Entry

For partial consumption with "Manufacture" Stock Entry

"Material Consumption for Manufacture"

"Manufacture" Stock Entry

djpalshikar · 2018-03-26T11:24:02Z

@creamdory

After consumption entry, Value of WIP Stock will go down by $1. And nothing else will be affected.
Although value of Stock at WIP is still the same. This could be an issue.
For users having Perpetual accounting enabled, I think you have got it right. But for users where accounting is not perpetual, they will have to manually take care of "Consumption Entries" and create a ledger.
Lastly someone from Frappe has to clarify if this will affect how Valuation Rate is calculated for items The article here https://frappe.erpnext.com/kb/stock/how-valuation-rate-is-calculated-for-an-item is silent on "Stock Entry for Manufacture"

nabinhait · 2018-03-26T12:07:57Z

Regarding accounting entry for "Material Consumption for Manufacture", let leave it to the users. Basically, user should be able to enter "Difference Account" manually and it can be either expense or asset account.
BY default, I will suggest to skip accounting entries for "Material Consumption for Manufacture". So, to do that we will set "Difference Account" as the WIP warehouse account. Hence, the system debit and credit the same account and resulting no accounting entries. And in "Manufacture" entry as well, we will set "Difference Account" as WIP warehouse. So, system will debit FG Warehouse account and credit WIP warehouse account.
If the user want to book expense while consumption, they can change it to "Cost of Goods Sold" account or any other.
If the user want to maintain another intermediate asset account, they can manually select that account in the consumption entry.

nabinhait · 2018-03-26T12:16:35Z

+		if self.work_order and self.purpose == "Material Consumption for Manufacture":
+			self.validate_work_order_status()
+		else:
+			self.update_stock_ledger()


update_stock_ledger should be outside else condition.

nabinhait · 2018-03-26T12:20:46Z

+		if self.purpose in manufacture_purpose and self.work_order:
+			if not frappe.get_value('Work Order', self.work_order, 'skip_transfer'):
+				item_code = []
+				for item in self.items:


This loop should only be run for raw materials. Add a if condition if cstr(item.t_warehouse) = '':

nabinhait · 2018-03-26T12:23:31Z

+						if stock_qty > trans_qty:
+							item_code.append(item.item_code)
+				if item_code:
+					frappe.throw(_("Consumption quantity cannot be more than transferred quantity for item/s {0}.").format(', '.join(item_code)), OverConsumptionError)


Should we do this validation? Because many cases, some unused raw materials (from earlier Work Orders) are there in WIP warehouse, which gets used. And it can lead to more consumption than transferred qty.

nabinhait · 2018-03-26T12:26:39Z

+			if (self.purpose == "Material Consumption for Manufacture" or self.purpose == "Manufacture"):
+				for items in self.items:
+					if self.docstatus == 1:
+						frappe.db.sql("""Update `tabWork Order Item` set consumed_qty = consumed_qty + %s


Always avoid codes like this which does "+" and "- for updating qty. Use sum of all consumed qty against the work order, similar to https://github.com/frappe/erpnext/blob/develop/erpnext/manufacturing/doctype/work_order/work_order.py#L498

creamdory · 2018-03-26T12:36:19Z

@nabinhait , what about the calculation of the Finish product valuation rate ?

Also, I wanted to confirm to you this:

I will suggest to skip accounting entries for "Material Consumption for Manufacture". So, to do that we will set "Difference Account" as the WIP warehouse account.

This means the stock is consumed and deducted in the system but with zero accounting entries? And how do we make all the entries during finish? Should we get component cost from all the "Material Consumption for manufacture" for a work order?

nabinhait · 2018-03-26T12:40:14Z

Can you add some docstrings in this whole calculation, to explain the use case?

nabinhait · 2018-03-26T12:48:52Z

This means the stock is consumed and deducted in the system but with zero accounting entries? And how do we make all the entries during finish? Should we get component cost from all the "Material Consumption for manufacture" for a work order?

Yes, it will not going to work, it is not that simple. What about if we book normal expenses while consumptions? And while updating finished goods, raw material expenses will be reverted, if we use same difference account. And expenses will be booked only for additional costs.
Now, the main challenge is updating valuation rate for FG item. Even if take consumed material costs, we don't know against how many FG items, those raw materials are consumed.

creamdory · 2018-03-26T14:50:55Z

@nabinhait , made the changes you requested. And about below:

Yes, it will not going to work, it is not that simple. What about if we book normal expenses while consumptions?

Currently, it is done like this now. "Material Consumption for Manufacture" behaves like a "Material Issue" only with tagged Work Order.

And while updating finished goods, raw material expenses will be reverted, if we use same difference account. And expenses will be booked only for additional costs. Now, the main challenge is updating valuation rate for FG item. Even if it take consumed material costs, we don't know against how many FG items, those raw materials are consumed.

Can't be done since there is an option to do consumption in the "Manufacture" stock entry too when booked "Material Consumption for manufacture" is not done fully for the fg_completed_qty. And yes it will be challenging in the valuation rate calculation that is why I have suggested a WIP account that will be reverted in the "Manufacture" stock entry.

nabinhait · 2018-03-27T10:34:35Z

@dottenbr @creamdory Documentation is updated for renaming Production Order to Work Order. You can start documenting this changes.

nabinhait

This entire functionality should be hidden by default. And can be enabled via a setting in Manufacturing Settings.

nabinhait · 2018-03-27T11:15:00Z

The same calculation is applicable if "Backflush Raw Materials Based On" is set as "BOM" in Manufacturing Settings. It should consider Consumption entry and pull only remaining items.

@nabinhait this is what this code do.

But I think it does not work if "Backflush Raw Materials Based On" is set as "BOM" in Manufacturing Settings. I think get_transfered_raw_materials is not called for that use case.

nabinhait · 2018-03-27T11:16:23Z

It should not be shown if all items are consumed

creamdory · 2018-03-28T10:28:01Z

@nabinhait

Material Consumption in "Manufacturing Settings"

nabinhait · 2018-03-28T10:31:16Z

@creamdory Change the label "Material Consumption" to "Allow Multiple Material Consumption".

creamdory · 2018-03-28T11:58:04Z

@nabinhait

creamdory · 2018-03-28T10:29:22Z

@nabinhait Added this to trigger get_transfered_raw_materials() without looking at the backlash_raw_materials_base_on

@creamdory It is not right. If "backflush_raw_materials_based_on" is based on BOM, then it should not consider transferred materials. It will simply assume all the items in the BOM is in WIP warehouses.

creamdory · 2018-03-29T12:42:51Z

@nabinhait requested changes made.

creamdory · 2018-03-29T13:41:09Z

@nabinhait currently, documentation is broken. https://discuss.frappe.io/t/bug-documentation-broken/601

creamdory · 2018-03-29T15:36:46Z

@nabinhait made the documentation. Please check.

djpalshikar · 2018-04-09T06:43:46Z

@creamdory is there decision on the valuation of the finished item ?

creamdory · 2018-04-09T06:45:50Z

@djpalshikar currently not automated. Nabin says to change accounts during Stock Entries. Though we will think about it and make some enhancements. Currently, this feature can be enabled or disabled for this case.

@nabinhait

…acture Hi @nabinhait , Issue : Manufacturing setting > Backflush Raw Material Based on “Material Transferred for Manufacture” doesn't fetch the actual raw material transferred qty. It fetches qty based on "BOM" The issue is because @creamdory in PR #frappe#13384 commit : https://github.com/frappe/erpnext/pull/13384/files#diff-91f0ed661ef4b6e1f167fc7961b1a79b ``` changed from: if trans_qty and manufacturing_qty >= (produced_qty + flt(self.fg_completed_qty)): to : if trans_qty and manufacturing_qty > (produced_qty + flt(self.fg_completed_qty)): ``` **'='** was added by her in the condition, which was not there before her commit. Kindly except the fix for the issue. https://github.com/frappe/erpnext/blob/develop/erpnext/stock/doctype/stock_entry/stock_entry.py#L1057 frappe#13384 https://github.com/frappe/erpnext/pull/13384/files#diff-91f0ed661ef4b6e1f167fc7961b1a79b **before fix gif** : Stock Entry = Manufacture shows raw material quantity as per BOM. ![FetchTransQtyError](https://user-images.githubusercontent.com/29812965/74123824-ffdd8600-4bf5-11ea-8873-95de24a7ef09.gif) **after fix gi**f : Stock Entry = "Manufacture" shows raw material quantity as per "Material Transfer for Manufacture". ![FetchTransQtyFix](https://user-images.githubusercontent.com/29812965/74123836-0c61de80-4bf6-11ea-86fb-d9619fd9b02b.gif)

creamdory added manufacturing newmatik.io feature-request labels Mar 24, 2018

creamdory requested a review from nabinhait March 24, 2018 09:32

creamdory changed the title ~~Work Order Material Consumption~~ [Enhancement] Work Order Material Consumption Mar 24, 2018

creamdory force-pushed the material_consumption branch from 452c533 to 1041ac5 Compare March 26, 2018 06:39

nabinhait requested changes Mar 26, 2018

View reviewed changes

creamdory force-pushed the material_consumption branch from adb0791 to 0fc10b0 Compare March 26, 2018 14:38

nabinhait requested changes Mar 27, 2018

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nabinhait added the waiting-for-fixes label Mar 28, 2018

nabinhait self-assigned this Mar 28, 2018

creamdory and others added 4 commits March 28, 2018 09:27

Work Order Material Consumption

1440af8

Test cases and other minor fixes

2c16a88

Test cases fixes

64ca68a

Travis Fixes

714c797

creamdory force-pushed the material_consumption branch from 0fc10b0 to dd39201 Compare March 28, 2018 08:18

creamdory force-pushed the material_consumption branch 3 times, most recently from dccf9c8 to 53068a6 Compare March 28, 2018 10:21

creamdory force-pushed the material_consumption branch from 53068a6 to 0894896 Compare March 28, 2018 11:57

creamdory commented Mar 28, 2018

View reviewed changes

creamdory force-pushed the material_consumption branch 3 times, most recently from 47864ca to 381e0e4 Compare March 29, 2018 12:03

creamdory force-pushed the material_consumption branch 2 times, most recently from 3b342b7 to 1988562 Compare March 29, 2018 13:08

Work Order Material Consumption Request Changes

98bcffe

creamdory force-pushed the material_consumption branch from 1988562 to 98bcffe Compare March 29, 2018 15:24

Update work_order.js

c13cad8

nabinhait merged commit ad76f9a into frappe:develop Apr 9, 2018

creamdory mentioned this pull request Apr 10, 2018

"Manufacture" Stock Entry and "Finish" Button #13370

Closed

2 tasks

dottenbr deleted the material_consumption branch October 25, 2018 06:00

ashish-greycube mentioned this pull request Feb 10, 2020

fix: backflush raw material based on - Material Transferred for Manufacture #20555

Merged

ashish-greycube mentioned this pull request Feb 10, 2020

fix: backflush raw material based on - Material Transferred for Manufacture #20556

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creamdory commented Mar 24, 2018

Usecases:

Usecase:

Usecase:

Usecase:

Validations

Notes

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