FrontAccounting forum — Advanced Manufacturing and My Doghouse

Re: Advanced Manufacturing and My Doghouse

null@example.com (Petros) — Sun, 18 Oct 2015 19:55:18 +0000

@Joe
I guess the most complex issues are resolved. For someone not referring to Inv.Val report, advanced assembly works at GL level. Exception is:
1) labour_cost column of stock_master table, upon 2nd batch production, if 2nd batch labour cost = 0, doesn't update with new average labour cost. Same to overhead_cost column.
2) Even on the 1st batch production, suppose the production takes 2 days and you insert:
day1 labor cost $150
day2 labor cost $20
Stock_master, labour_cost column overwrites $150 by $20 instead of adding up.

Whoever can dig deep, can take up the challenge from here.

Re: Advanced Manufacturing and My Doghouse

null@example.com (joe) — Sun, 18 Oct 2015 09:17:14 +0000

@Petros

Thank you for your persistent testing . Please download and replace from the above links again (they have been updated):

/manufacturing/includes/db/work_order_produce_items_db.inc
/manufacturing/includes/db/work_orders_db.inc.

I guess this is as long as I can go with the fixing. It is very complex routines. It also handles ev. negative stock if set etc. Many things to take care of. Digging deaper will require assistance from a skilled programmer that are also familiar with the Advanced Assembly.

/Joe

Re: Advanced Manufacturing and My Doghouse

null@example.com (Petros) — Sat, 17 Oct 2015 20:31:06 +0000

@Joe
Thank you for your attention to the problem and prompt responses.
I now have accuracy issues: to replicate my situation:
1. Just restore to previous backup (https://drive.google.com/file/d/0B8DlmARQ8isNM01BeE03Mzd1Qjg/view?usp=sharing)
2. Receive the outstanding p.o >> produce 1 qty of Output1 with $41.4 add.material, $150 labor and $50 Overhead costs.
3. Right away make a 2nd batch production of 3qty of Output1 with $41.4 add.material, $150 labor and $50 Overhead costs.
Now you're supposed to get this:https://drive.google.com/file/d/0B8DlmARQ8isNWGo4RnlHVUxtdE0/view?usp=sharing
But you get this: https://drive.google.com/file/d/0B8DlmARQ8isNNzdrbks3Q1Nid28/view?usp=sharing

* I still see that received p.o. items, appear at a rounded rate in material_cost column, understating the value of inventory. I've agreed with @apmuthu in another thread that rounding is waived at storage level to maintain accuracy and should only apply at display level.

Re: Advanced Manufacturing and My Doghouse

null@example.com (joe) — Sat, 17 Oct 2015 12:57:07 +0000

Hello,

Here are the new files. They have been committed to repo. replace on your server.

/manufacturing/work_order_costs.php
/manufacturing/includes/db/work_order_produce_items_db.inc
/manufacturing/includes/db/work_orders_db.inc
/manufacturing/includes/db/work_orders_quick_db.inc

@Petros

Remarks to your readme.txt file:

2.a. The issue of 10 'input 1' should NOT be devided by any factor to add the material cost per item price. This is the issue for 1 'Output 1' item.
The Worth of the 10 'input 1' was $41.40 (not $44.10).

/Joe

Re: Advanced Manufacturing and My Doghouse

null@example.com (joe) — Sat, 17 Oct 2015 10:17:28 +0000

@Petros,

Thanks for the test material. It was nice to make the tests from here.

I have fixed the issues, but want to do some further tests Before releasing the files.

I will be back later.

/Joe

Re: Advanced Manufacturing and My Doghouse

null@example.com (Petros) — Fri, 16 Oct 2015 21:31:28 +0000

Hi there,
Sorry for the delay: here's a link
https://drive.google.com/file/d/0B8DlmARQ8isNM01BeE03Mzd1Qjg/view?usp=sharing
I included a helpful readme.txt file (which is why I delayed).

Re: Advanced Manufacturing and My Doghouse

null@example.com (apmuthu) — Fri, 16 Oct 2015 17:53:08 +0000

@Petros: Please provide a backup of the state before the Work Order commences and the steps thereafter to recreate your errors. You should have started from a fresh en_US-new.sql install.

Re: Advanced Manufacturing and My Doghouse

null@example.com (joe) — Fri, 16 Oct 2015 15:05:56 +0000

@Petros.

I cannot reproduce your assembly errors.

Will you please give me a detailled example with amounts etc. If there still are errors, I will be extremely glad to fix these,

Joe

Re: Advanced Manufacturing and My Doghouse

null@example.com (Petros) — Fri, 16 Oct 2015 13:51:45 +0000

@Joe
$use_costed_values must remain zero at all times for accounting sake. It includes tax values in to inventory cost and then separately reports tax in liability, causing double consideration of tax in the gl.
Coming to advanced assembly:
On a fresh install as well, I see our recent fixes are advantageous to post production costs to the right assembly account but, behind the screen:
* Labour and overhead costs are not picked up by their respective stock_master columns
* Additional issues properly picked up by material_cost column during production eventually gets overwritten by BOM value post production (instead of adding up)
* Upon purchase, the material_cost column improperly does rounding to the unit rate.
I guess these are the problems and all other disparities are by-products of these same points.

Re: Advanced Manufacturing and My Doghouse

null@example.com (apmuthu) — Fri, 16 Oct 2015 08:23:27 +0000

@Petros: does this work on a new install as desired?
Even if so, what are the standard operating procedures to be followed for Advanced Manufacturing?
Should we set the config flag $use_costed_values?
Are there any advantages prior to using code prior to these last 2 commits?

Re: Advanced Manufacturing and My Doghouse

null@example.com (joe) — Fri, 16 Oct 2015 06:38:45 +0000

@Petros,

It can be a Little tricky to test this on an existing assembled item.

When Selling the item (delivery) it takes the Average Standard Cost to credit the Stock of Finished Goods (FG). Material, Labour and Overhead COSTs.This is done correctly.

The Item Valuation Reports can be a Little tricky also to follow.

There is a flag in config.php, called $use_costed_values, that usually is set to 0. Check that this is so. Then the reports are based on the overall average standard cost values. IF set to 1 it will use the average material COSTs over time. Maybe more correct related to the GL reports.

When testing, please start on a fresh Advanced Assembly Product, because we will get false tests otherwise.

Thanks for participating is this valuable test.

/Joe

Re: Advanced Manufacturing and My Doghouse

null@example.com (Petros) — Thu, 15 Oct 2015 22:34:10 +0000

@Joe
Back to advanced assembly:
Something remains a disparity between ledger account cost record and the database.
Suppose you produce a product with a $10 BOM, $5 additional issuance, $4 labour & $2 overhead cost:
*The finished goods account receives all $21 (this is where it's improved) but leaves behind the non-BOM costs upon sale of the item. Leaving FG account with leftover $11.
*Stock_master picks up only the $10 and distributes it over material_cost, labour_cost and overhead_cost columns using some strange ratio, I'm still trying to figure out: and this ruins INV. VAL report.
*I noticed that when you issue additional materials, it goes correctly to material_cost column but eventually gets overwritten (instead of adding up) by info from BOM when WO is closed.
*Suppose you produce an item without BOM, simply by a series of issuance of materials and other costs on top, stock_master does receive what ever is given, so does the gl, but after "process" is clicked, stock_master nullifies its column values, while assembly account gets stuck with dissociated costs that remain there even if the item is sold out and, Inv Val report rates the item @ 0.
I guess they all mean the same thing == dissociation.

Re: Advanced Manufacturing and My Doghouse

null@example.com (Petros) — Thu, 15 Oct 2015 20:06:31 +0000

First thing is first. Recent corrections aiming at advanced manufacture caused material_cost column of stock_master to start rounding figures to user_decimal() for purchased items only. This causes:
* Understatement of the value of inventory while passing through one production phase to another.
* Distorts the weighted average accuracy we used to find on inv.valuation report.

Re: Advanced Manufacturing and My Doghouse

null@example.com (joe) — Thu, 15 Oct 2015 08:38:44 +0000

Hello again,

The Standard Costs are now updated correctly when producing an Advanced Assembly.

You should now be able to run the valuation reports correctly.

Please download the following files and replace.

/manufacturing/includes/db/work_order_produce_items_db.inc
/manufacturing/includes/db/work_orders_quick_db.inc

Unfortunately I am not able to fix the stand alone button for 'Close' at the moment. The algorithms are now dependent of the production.
Your stock will not get updated only with adding Costs and issues. Only during the production the standard Costs are updated.

This is the reason why it is difficult to just enter additional Costs after all the production is done.

I am sorry for that, but maybe something shows up during the 2.4 release. Then of course we will fix this.

/Joe

Re: Advanced Manufacturing and My Doghouse

null@example.com (joe) — Wed, 14 Oct 2015 16:25:19 +0000

Yes, I know where the problem is. I need some additional time to correct this.

Joe