Manufacturing Detail Labor Reporting

Dynamics GP has multiple mechanisms to record labor and machine transactions to calculate costs during manufacturing production. Time and Machine transactions can be entered through either the Time Card Entry or Data Collection Window. The tables populated by these two windows are different tables altogether.

Work In Process reporting and inquiry tools begin with the selection of the source of the data and provides the ability to sort and filter data by key fields, which makes WIP reporting intuitive from within Dynamics GP. 

That being said, it is not uncommon for users to desire very specific report designs to meet users' needs.  Additionally, SQL Server Reporting Services, Analysis Cubes and other tools are provided expressly because, not every constituent needs nor has access to Dynamic GP. 

Consequently, when generating tools-based reports on WIP labor detail, it is important to know which tool is being used to collect the data, and which tables contain the associated records.

The Data Collection window is a common way to enter labor (direct and indirect) as well as machine costs for work orders. With a simple wedge scanner and some well-placed barcode font, entering data in this window is fast and accurate. This approach is commonly used when there is a central location in the shop, where work order data is collected. The Data Collection window can be accessed using the following navigation: 

(Manufacturing > Transactions > WIP > Data Collection).

Data entered in the Data Collection window is stored in the SF010014 - Data Collection Master and SF010115 - Data Collection Line Items tables (most of the relevant data is stored in the SF010115 table). When joined to the UPR00100 - Employee Master and LC010014 - Labor Code Master tables, a complete picture of detailed labor transactions is achieved.  Here is a basic query, which returns all labor related transactions from the SF010115 table.

NOTE: The Labor Code Master table contains the Shop Rate for the Labor Code, which will be used if the Employee does not have a specific value assigned for the Labor Code in Payroll Setup. The query below assumes the shop rate is used.

-- Labor Detail when entered in Data Collection Window

Select

DCT.MANUFACTUREORDER_I

,DCT.RTSEQNUM_I

,CASE DCT.DATAENTRYTYPE_I

      when 1 then 'Direct_Labor'

      when 2 then 'Machine_Cost'

      when 3 then 'Indirect_Labor'

ELSE 'ERROR'

End Entry_Type   

,DCT.EMPLOYID Employee_ID

,RTRIM(RTRIM(EMP.LASTNAME)+', '+RTRIM(EMP.FRSTNAME)+' '+RTRIM(EMP.MIDLNAME)) Employee_Name

,LCD.COST_I ShopRate

,DCT.ELAPSEDTIME_I Elapsed_Time

,DCT.SEQUENCECOST_I Labor_Cost

,DCT.FIXOVERMARK_I Fixed_Overhead

,DCT.Variable_Overhead_Amount Variable_Overhead

,DCT.PIECES_I Pieces

,DCT.REJECTS_I Rejects

,DCT.PIECECOST_I Piece_Cost

,CONVERT(varchar(10),DCT.ACTUALFINISHDATE_I,101) Finish_Date

from SF010115 DCT

left join LC010014 LCD on DCT.LABORCODE_I = LCD.LABORCODE_I

Left join UPR00100 EMP on DCT.EMPLOYID = EMP.EMPLOYID

Where DCT.DATAENTRYTYPE_I in (1,3)

Alternatively, the Time Card Entry window can be used to enter Detailed Labor data into Dynamics GP. The Time Card Entry window is an employee based entry system, and is more frequently used when each work-center/employee has access to the window, and updates their time data throughout the day. The Time Card Entry window can be accessed using the following navigation:

(Manufacturing > Transactions > WIP > Time Card Entry)

Time Card Entry data is stored in the SF010600 - DC_Labor_Batch_Entry_Hdr and SF010601 - DC_Labor_Batch_Entry_Dtl (Data Collection Labor Batch Entry Header and Detail) tables. These tables contain a wealth of data and therefore do not require links to additional tables. 

-- Labor Detail when entered in Time Entry Window

select * from SF010600 TEH

left join SF010601 TED on TEH.DCHDRNUM_I = TED.DCHDRNUM_I

Feel free to reach out to me, should you have questions about Detailed Labor Reporting for WIP in Dynamics GP Manufacturing.

Dynamics GP 2013 Manufacturing Work Order Transactions with Posting Summarized

I recently put together a specification for customization, which is intended to automatically issue materials to work-centers as work orders move through their routing steps.   This customization relies on a custom Production Management window which handles the work-flow of completing routing steps, ordering rework and picking the routing step to return the work order to if rework is necessary, etc.  

The customization also issues additional material automatically, if rework is required for a previously completed step. This paperless system enables the flow of work orders from one work center to the next by pointing and clicking.

Prior to signing off the CFO asked a series of questions about the impact this would have on financial transactions - in order to sum up the changes, I found it necessary to create an overview of what happens when processing a manufacturing work order to compare and contrast standard to custom. 

This is a simple overview, which doesn't cover automated data collection, or outsourced manufacturing, but it does cover straight forward work order processing in Dynamics GP succinctly.

Standard GP Manufacturing Process - Make to Order

A Work Order must be released prior to performing any transactions against it – nothing can be done to a work order prior to it being released other than changing it's status.

Valid Manufacturing Order Status are:
Quote/Estimate
Open
Hold
Cancelled
Partially Received
Complete
Closed

Manufacturing transactions can be entered using the Component Transaction Entry window. 

Transactions > Manufacturing > Component Transaction Entry

Transaction Types allowed in the Component Transaction Entry window are Allocation, Issues and Scrap (and the reverse of these transactions)

Alternatively the Picklist window can be used to backflush (or reverse-backflush) materials for work orders.  

Transactions > Manufacturing > Picklist 

Backflush - is the process of assuming the materials consumed by a work order are consistent with the quantities defined in the item's Bill of Materials 

(Qty  Made * Quantities to make one item = Total Material Consumed)

Backflushing is easiest way to conduct  manufacturing operations and the least accurate.  Backflusing assumes everything goes to plan all the time - in my experience it rarely does.

Since it is unnecessary to Allocate or Issue materials to work orders - most material transactions are optional.

Optional Transaction 1 – Raw Materials can be Allocated to the Work Order

This can be done manually or automatically.  To configure Dynamics GP to allocate Raw Material Inventory automatically when a work order is released use the following setting

The automatic function in GP allocates all required materials immediately 

Setup > System Defaults > Manufacturing Orders

Allocation – Decreases inventory on hand, but has no financial impact (no GL transactions are posted)

Optional Transaction 2 – Raw Materials can be Issued to the Work Order, Issues move Raw Materials Inventory (RMI) to Work in Process (WIP) manually – 

Standard GP functionality cannot automate material issues.

Issues – Decrease the inventory on hand, AND have a financial impact
(Credit Raw Materials Inventory and Debit Work In Process)

Optional Transaction 3 – Raw Materials can be scrapped
(Credits Raw Materials Inventory and Debits Scrap)

Optional Transaction 4 – Cancel MO:  
Users must manually reverse issues and allocations of materials
(Credit WIP and Debit Raw Materials Inventory [RMI])

AND/OR use Scrap, to write off materials that can’t be return to inventory.
(Credit RMI and Debit Scrap - see Optional Transaction 3 above)

Optional Transaction 5 – Rework.
Material must manually be issued to the MO 
(Credit Raw Materials Inventory and Debit WIP)
This is done until workers get the Work Order right – variance posted later.

Optional Transaction 6 – customer wants  an alternative configuration

Materials are manually added or removed - a.k.a. Soft Bill Changes
(Credit/Debit Raw Materials Inventory and Debit/Credit WIP)
Added items Credit RMI and Debit WIP
Removed items Debit RMI and Credit WIP

Manufacturing Order Receipts move Raw Materials Inventory or WIP to Finished Goods Inventory, depending on whether backflushing is being used or issues were done respectively. 
(Credit WIP/RMI and Debit Finished Goods Inventory)

Manufacturing Order is Completed – no more data can be collected against the MO, no more materials issued, or receipts reported.  No Financial Transaction happens at this step. This is very important, as failing to Close Completed work orders will not provide an accurate picture of inventory or finances related to inventory.

Manufacturing Order is Closed – WIP variance transactions cleared to Variance Account. Closing work orders is and absolutely necessary step! 
(Credit WIP and Debit Material Variance and Finished Goods Inventory)

Finished Goods Allocated / Fulfillment of Sales Order

Item Ships and is Invoiced – Move Finished Good from Inventory to COGS 
(Credit Finished Goods Inventory and Debit Cost of Goods Sold [COGS])

Feel free to ask questions or take umbrage with my assertions. I hope this gets you where you're going.