Does your accounting staff spend excessive time entering each component of a finished good into your software, in order to take the item out of inventory? Does your warehouse staff struggle with which items to pull in order to begin a manufacturing run? Are you in the dark about your true manufacturing costs and profitability? These are just some of the question that may be solved if you start to use assemblies within your manufacturing management software. Learn more about the terms associated with assemblies, and how they can work together to help your manufacturing business become more organized, operate more efficiently, and increase profitability.

Assemblies Maintenance

Assemblies Maintenance is the process of defining which components or parts make up your finished item. The finished item is known as an assembly. Most manufacturing management software will let you create an assembly with all of its components as well as labor (often set up as a ‘service’ inventory item), so that true costs may be calculated. The system may also allow you to include costs from outside services, such as sending out an item to have it painted, which can be helpful if the components require other services before being included in an assembly. Once the assembly for a standard assembly item has been created and saved within your software system, that assembly can be used again and again. You may choose to copy a previously saved assembly and customize it for a different customer, saving significant time.

Assemblies Production

A production plan is a sequential list of assemblies to be built, one at a time. During this ‘building’ process, components are removed from inventory. Many systems will also allow for ‘un-building’, which put components back in inventory, helpful when an assembly was not completed or an order was cancelled. This eliminates the need to remove (or return) individual item components from your software system, as all components are simultaneously removed when the build is completed. Prior to the creation of a production plan, a shortage report can be generated to verify whether all needed items are available in stock. Once the actual physical building of the item is completed on the shop floor, the assembly is then built within the software.

Serial and Lot Numbered Items

Some components within an assembly may contain lot or serial numbers. If you record and track the numbers for each of these components as you receive them into inventory, you may also be able to select which serial/lot number is being used as a component within the assembly you are building. This is an important feature for those who wish to keep tracking the number of the component, even after it has been built into an assembly. If this is a feature you require for your manufacturing operation, be sure to choose a system that allows for that capability.

Bill of Materials

The bill of materials is a document that shows all of the information about a production plan, including its assemblies and required components. This document can be created by the software system once a production plan has been created within the system. The bill of materials typically shows the quantity of components that are needed, and also the quantity that is currently on hand, so that missing components can be put on order. The bill of materials is also useful for warehouse staff, as it provides a comprehensive list of items that need to be pulled for a product run.

Setting up assemblies within your manufacturing management software can greatly help increase efficiency and profits for your manufacturing operation.

The shipping department: probably not the most profitable department of your entire company. No wonder so many companies decide not to put a computer back there -- just another added expense. Not only does the computer cost money, but then there is the upkeep to hardware and software as time goes on. On the other hand, adding a computer to the shipping area might just be one way to add more profits and streamline processes. What most businesses don’t consider is the amount of efficiency they will gain by adding a computer to the shipping department. Here are some time and money saving functions you can achieve by adding a computer in your shipping department.

• Using the accounting software or order entry system, the shipping department knows which orders need to be shipped without the office having to print a copy of the order and manually bring it back to them.
• The shipping department can document on their computer how many of each item they actually ship, and they can also print a packing slip to put in the box. This saves from having to tell the office what will ship and then wait for them to print the packing slip, or having the office print a packing slip and the shipping department hand-writing changes on it.
• Because the shipping department is documenting on their computer how many are shipped, there is no need for them to remember to tell the office that they weren’t able to ship all quantities, so invoicing is consistently more accurate.
• Shipping charges are more accurate, since the shipping department is able to put actual shipping costs on the order while they fill it. This also allows the invoice to be finalized quicker.
• By having the shipping department fill orders on the computer in accordance with what shipped, inventory is deducted as soon as it’s shipped, as compared with being deducted when the office gets the paperwork. The office can pull up the shipped orders on the computer and see exactly what shipped or which items may need to be put on backorder.
• All of these functions result in orders being filled more promptly, which means the invoice is ready to go to the customers more quickly, which in turn may lead to quicker payments from customers.

If the above functions fit for your company, you might want to try adding a computer to the shipping department and see if your processes can be streamlined. All of the steps saved can really add up over a year. Streamlining the process gives your office/sales people more time to sell and allows the shipping department to more efficiently complete their tasks.

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Keeping your inventory counts accurate not only increases profits, it also reduces frustration and saves time. Here are some simple tips to keep your inventory numbers accurate.

• Start doing random checks of three to four items, every other day for a couple of weeks, or until discrepancies are found. The main reason for inaccurate inventory count is that not all transactions get into the system. By doing checks every other day, the transactions are fresh, and you can remember the transactions that might have been forgotten or missed.
• If an inaccuracy is spotted, start tracking where that item went. Normally, you will find that the item was used internally, or it was used to fix another part, or someone picked it up and the sale wasn′t written down. Check those places first!
• Make spot checks a part of your internal processes. This will enlighten you and those at your company as to where changes need to be made.

Once you make spot checks for inventory part of your ongoing processes, you will find that your inventory accuracy improves, frustrations are minimized, and less time is spent resolving end of year physical inventory counts. It′s a win-win situation for everyone involved!

This is part of Accounting Software Helps You Go Paperless, continued from the prior blog post.

Create, send and track purchase orders electronically.

Do you run out of your most popular products, while the slow movers just keep sitting on the shelves? Are you unsure of how many of an item to order? Perhaps you have a giant folder labeled with your vendor’s name that is overflowing with paper copies of purchase orders and other vendor information. These are just a couple of the major functions that can be solved by electronic purchase order management. A purchase order system within your accounting software can suggest, produce, process and receive purchase orders for items and/or services. Your whole purchasing process is made more efficient, and will save money by having the right products on your shelves at the right time, when customers need it.

Create and send reports within the system and via e-mail.

Most companies run their financial reports every month, print them and distribute them to the appropriate parties. The reports are typically viewed and then stored or disposed of. By distributing reports via e-mail instead of in print, you will save on paper and also reduce the chances of sensitive financial information going around the office. Also, create the reports in Adobe PDF files, and everyone (even those without your accounting software) will be able to easily view the reports. Your data is safe and accurate in a PDF format as it allows the user to make notes on the report but won’t allow them to change the original.

Cut down on printed invoices and statements.

Yes, it’s an old habit that’s hard to break. But think about it, do you really need all those printed copies of invoices and statements? A good accounting software program should allow you to reproduce/reprint any invoice or statement from history, so there’s really no reason to keep a copy. If you want to keep copies so people without authorization to the accounting software can view them, you should print to PDF files (which does not physically print them but instead saves them into a PDF format) and keep them in a safe/organized place on the server. To do this, just name the file and folders the same way you would if it was a file cabinet. If you would normally have a file cabinet full of folders for each customer, then you would create a folder on the server called “Invoices”. And within that folder, you would have a separate folder for each customer. When you print the invoices to PDF files, you would name them with the customer code and invoice number, and save them within the appropriate customer file.

On the other hand, some businesses now keep a three-ring binder that has a copy of every invoice/statement in it, sorted by invoice number. If you are currently doing this and would like to continue doing it with electronic copies, then you would create a folder on the server called “Invoices”, and all invoices would be saved in that folder. When you print the invoices to PDF, use the invoice number as the file name, or the invoice number and customer code.

Don’t forget that there’s always the possibility of having an interim period where you still print a copy and then keep a PDF copy. However, this often leads to employees reverting back to old ways, so it’s typically best to make the change ‘cold turkey’.

Old habits die hard, but going paperless or at least reducing the amount of paper you use can greatly benefit your business and our environment. Let accounting software help you and your business on your path to going paperless!