@corbincavolt: I feel your pain. For a company into building made to order equipment, the way I have over come this issue is to create virtual warehouses called ProductionStation1, 2,… We designate a Production Station as the virtual warehouse for a particular project. This warehouse will only be used for this project and nothing else. Till the project is complete and the project debriefing is conducted and the follow up action from the debriefing is completed, we use this Production Station only for this project.
@umag has helped us create a custom report that lists the stock availability of a given BoM. We use this report to plan procurement of materials. Then we drop all materials that are required for the manufacture of this item (as per BoM) into this Production Station (which is, like I said, a virtual warehouse). The BoM Stock Report, when you select the BoM and the Production Station warehouse will tell you whether you have already issued raw material and components for manufacturing a particular component/assembly.
As sub assemblies are manufactured, we “consume” the raw material/components necessary to make that sub assembly.
As, seemblie3s are made and the product is built, you could have two situations:
A component that is needed is not issued into the Production Station - When this happens, the manufacturing entry for the assembly/product cannot be submitted as ERPNext will say that component is not there in stock. You do a quick investigation and figure out whether the operators, managed to lay their hands on the component, say on the shop floor, or whether the BoM was wrong and didn’t really need this component. Or that the stores incharge missed out making an entry for this component. If the BoM is wrong you correct the BoM for the next time and boom you have a self healing, self correcting organization.
There are left over raw material or components once the project is manufactured. This could indicate that there was (a) Bad quality and operators needed to draw the raw material or component again, (b) The Raw Material or component is not really required (Correct the BoM) - this will be indicated by those excess raw material/components being available at the Production Station for return to stores), © Or that the operators missed including this raw material/component in the product (boom you have a self correcting process).
Now the custom report that @umag created is at the BoM level, with slight tweaking, you can do a similar report for the Production Order and that will help you manage your manufacturing reasonably elegantly, till we enhance the manufacturing module. Uma can help you if you need any assistance.
This approach should work for all types of manufacturing: Projects, Machines, Assembly Lines, Process Industries, etc. with only slight modifications.
I agree that these are mere workarounds and the manufacturing module needs to take care of the realities of the shop floor. We are actively working to enhance the manufacturing module and it would take months or quarters and this approach should help you reduce complexity in the interim.
We DEFINITELY DO need to enhance the manufacturing module, so your (and everybody’s) contributions in terms of intellect, time, resources and money will help us kick SAP’s (nothing personal against SAP, but it is the poster child of the big, bad, expensive ERP) butt!!