Access the Demo Environment

• URL: demo-v1.bigledger.com
• Username: demo-mfg (Manufacturing Manager)
• Password: Demo2025!
• Company: AcmeMfg Industries

This account has full access to manufacturing modules and pre-configured sample data.

Pre-loaded Test Data

• Raw Materials: 50+ components (resistors, capacitors, chips)
• Work Centers: Assembly line, SMT line, Testing station
• BOMs: Multi-level structures for 5 main products
• Vendors: 15 suppliers with lead times and pricing
• Customers: 20 customers with production orders

Sample Products

• AC-SENSOR-001: Automotive temperature sensor
• PC-BOARD-LCD: LCD display circuit board
• SW-MODULE-RF: RF communication module
• CABLE-HARNESS: Wire harness assembly
• HOUSING-ALU: Aluminum housing unit

1. Access BOM Management

1. Login to demo environment
2. Navigate to Manufacturing → Bill of Materials
3. Click + New BOM
4. Select Product: AC-SENSOR-001
5. Set BOM Type: Manufacturing
6. Enter Version: V1.0
7. Set Effective Date: Current date

Expected Result: New BOM header created with product details loaded.

2. Add BOM Components

Main Assembly Components:

1. Click Add Component

2. Add these items with quantities:

   • Sensor chip (IC-TEMP-DS18): 1 EA
   • PCB board (PCB-SENSOR-01): 1 EA
   • Resistor 10K (R-10K-0805): 2 EA
   • Capacitor 100nF (C-100N-0805): 1 EA
   • Connector 3-pin (CON-3PIN-JST): 1 EA
   • Housing plastic (HSG-PLAST-01): 1 EA

3. Set Unit of Measure for each component

4. Define Scrap % (typically 2-5% for electronics)

5. Set Lead Time for each component

Expected Result: Complete component list with quantities and specifications.

3. Define Routing Operations

1. Click Routing tab

2. Add these operations in sequence:

   • Op 10: SMT Assembly (Work Center: SMT-LINE-01)
   • Op 20: Through-hole insertion (Work Center: ASSEMBLY-01)
   • Op 30: Soldering (Work Center: SOLDER-01)
   • Op 40: Testing (Work Center: TEST-STATION-01)
   • Op 50: Housing assembly (Work Center: ASSEMBLY-02)
   • Op 60: Final inspection (Work Center: QC-STATION-01)

3. Set Setup Time and Run Time for each operation

4. Define Labor Cost and Machine Cost rates

Expected Result: Complete routing with time standards and cost information.

4. BOM Validation

1. Click Validate BOM

2. System checks:

   • Component availability
   • Vendor sources
   • Cost completeness
   • Routing consistency

3. Review validation results

4. Fix any warnings or errors

5. Click Approve BOM

6. Set status to Active

Expected Result: Validated and approved BOM ready for production use.

1. Set Up Demand Sources

1. Navigate to Planning → Demand Management

2. Review Sales Orders requiring production:

   • SO-2025-001: 100 units AC-SENSOR-001 (Due: Week 2)
   • SO-2025-002: 50 units PC-BOARD-LCD (Due: Week 3)
   • SO-2025-003: 200 units SW-MODULE-RF (Due: Week 4)

3. Check Forecast Demand:

   • Click Demand Forecast
   • Review forecasted quantities by product
   • Adjust forecast if needed

4. Verify Safety Stock Levels:

   • Go to Inventory → Item Master
   • Check safety stock settings for finished goods

Expected Result: Complete demand picture including firm orders and forecasts.

2. Execute MRP Run

1. Navigate to Planning → MRP Planning

2. Click New MRP Run

3. Set Planning Parameters:

   • Planning Horizon: 12 weeks
   • Bucket Size: Weekly
   • Include Safety Stock: Yes
   • Consider Work Calendar: Yes

4. Select Products to Plan:

   • All finished goods
   • Key sub-assemblies
   • Critical raw materials

5. Click Run MRP

6. Monitor progress in MRP Run Status

Expected Result: Completed MRP run with supply recommendations generated.

3. Analyze MRP Results

1. Open MRP Results Dashboard

2. Review Exception Messages:

   • Late orders
   • Capacity constraints
   • Material shortages
   • Policy violations

3. Check Planned Orders:

   • Production orders to be created
   • Purchase orders needed
   • Timing and quantities

4. Review Capacity Analysis:

   • Work center loading
   • Bottleneck identification
   • Overtime requirements

Expected Result: Clear understanding of production requirements and constraints.

4. Take Planning Actions

Create Production Orders:

1. Select planned production orders
2. Click Create Production Orders
3. Review and confirm order details
4. Set priority levels

Generate Purchase Requisitions:

1. Select material requirements
2. Click Create Purchase Requisitions
3. Assign to appropriate buyers
4. Set required delivery dates

Handle Exceptions:

1. Review capacity overloads
2. Reschedule non-critical orders
3. Consider subcontracting options
4. Adjust safety stock if needed

Expected Result: Actionable production and procurement plan ready for execution.

1. Create Work Order

1. Navigate to Manufacturing → Production Orders

2. Click + New Production Order

3. Enter order details:

   • Product: AC-SENSOR-001
   • Quantity: 100 units
   • Due Date: Next Friday
   • Priority: Normal

4. System auto-populates:

   • BOM components
   • Routing operations
   • Standard costs

5. Review and confirm order

6. Click Release Order

7. Order status changes to Released

Expected Result: Work order created and ready for material planning.

2. Material Issue Process

Issue Materials to Production:

1. Click Issue Materials from work order

2. Review material requirements:

   • Quantity needed vs available
   • Batch/serial requirements
   • Expiry date checks

3. For each component:

   • Select stock location
   • Choose specific batches if required
   • Confirm quantities

4. Click Issue All Materials

5. System updates:

   • Inventory balances
   • Work order status
   • Material costs

Expected Result: All materials allocated to production order.

3. Production Tracking

Operation Reporting:

1. Go to Shop Floor → Operation Reporting

2. Select work order and operation

3. Report production progress:

   • Quantity completed: Enter actual production
   • Labor hours: Record actual time spent
   • Machine hours: Log equipment usage
   • Defects: Record any quality issues

4. For each operation (Op 10-60):

   • Start operation
   • Record completion
   • Move to next operation

5. System tracks:

   • Real-time progress
   • Actual vs standard costs
   • Efficiency calculations

Expected Result: Complete production tracking with cost accumulation.

4. Order Completion

Final Steps:

1. Complete final operation (Op 60)

2. Record final inspection results

3. Click Complete Order

4. Choose completion type:

   • Full completion: All quantities produced
   • Partial completion: Some quantity variance

5. Goods Receipt:

   • Specify storage location
   • Generate batch/serial numbers
   • Update inventory balances
   • Calculate final product cost

6. Order Closing:

   • Review cost variances
   • Close remaining material issues
   • Update production statistics
   • Archive order documents

Expected Result: Finished goods in inventory with accurate standard cost.

1. Incoming Material Inspection

Setup Inspection Plans:

1. Navigate to Quality → Inspection Plans
2. Create plan for IC-TEMP-DS18 (Temperature sensor chip)
3. Define inspection criteria:
   • Visual inspection: Packaging integrity
   • Electrical test: Resistance measurement
   • Functional test: Temperature accuracy
   • Documentation: Certificate of compliance

Execute Incoming Inspection:

1. Go to Quality → Inspection Orders
2. Select incoming shipment
3. Create inspection order
4. Record test results:
   • Sample size: 10 pieces from batch
   • Pass/fail criteria for each test
   • Measurement data entry

Expected Result: Approved materials ready for production use.

2. In-Process Quality Control

Setup Process Checkpoints:

1. Define quality checkpoints in routing:
   • After SMT: Solder joint inspection
   • After Assembly: Dimensional checks
   • After Testing: Functional verification

Execute In-Process Inspection:

1. At each checkpoint:

   • Record operator performing inspection
   • Document measurement results
   • Note any defects found
   • Apply corrective actions

2. Statistical Process Control:

   • Monitor control charts
   • Track process capability
   • Identify trends and patterns
   • Trigger alerts for out-of-control conditions

Expected Result: Process quality monitored and controlled throughout production.

3. Final Product Inspection

Comprehensive Final Testing:

1. Navigate to Quality → Final Inspection
2. Select completed work order
3. Execute test sequence:
   • Functional test: Full operational check
   • Calibration: Sensor accuracy verification
   • Environmental test: Temperature cycling
   • Durability test: Vibration resistance

Quality Data Collection:

1. Record detailed measurements
2. Capture test equipment used
3. Document environmental conditions
4. Note inspector certification
5. Generate quality metrics

Disposition Decision:

• Accept: Move to finished goods
• Reject: Return to rework
• Hold: Pending further evaluation

Expected Result: Quality-assured products ready for shipment.

4. Quality Certificates and Traceability

Generate Certificates:

1. Go to Quality → Certificates
2. Select products for certification
3. Generate Certificate of Compliance:
   • Product specifications met
   • Test results summary
   • Quality system compliance
   • Authorized signatures

Traceability Documentation:

1. Material Traceability:

   • Component batch numbers
   • Supplier information
   • Receipt dates

2. Process Traceability:

   • Production order details
   • Operator records
   • Equipment used
   • Process parameters

Compliance Reporting:

• Monthly quality metrics
• Customer quality reports
• Regulatory compliance documentation
• Corrective action tracking

Expected Result: Complete quality documentation package for customer delivery.

1. Configure Costing Methods

Standard Costing Setup:

1. Navigate to Accounting → Product Costing
2. Select product AC-SENSOR-001
3. Set up Standard Cost Elements:
   • Material Cost: $12.50 (from BOM)
   • Labor Cost: $3.20 (from routing)
   • Overhead Cost: $2.80 (allocated)
   • Total Standard: $18.50

FIFO/LIFO Configuration:

1. Go to Inventory → Valuation Methods
2. Set raw materials to FIFO
3. Set finished goods to Standard Cost
4. Configure work-in-process to Actual Cost

Cost Roll-up Process:

1. Run Cost Roll-up calculation
2. Update standard costs quarterly
3. Review and approve cost changes

Expected Result: Consistent costing methodology across all products.

2. Production Variance Analysis

Collect Actual Costs:

1. Navigate to Manufacturing → Cost Analysis
2. Select completed work orders
3. Review actual costs vs standard:
   • Material Usage: Actual vs BOM quantities
   • Labor Efficiency: Actual vs standard hours
   • Overhead Absorption: Applied vs actual

Calculate Variances:

1. Material Variances:

   • Price variance: (Actual price - Standard price) × Actual quantity
   • Usage variance: (Actual quantity - Standard quantity) × Standard price

2. Labor Variances:

   • Rate variance: (Actual rate - Standard rate) × Actual hours
   • Efficiency variance: (Actual hours - Standard hours) × Standard rate

3. Overhead Variances:

   • Spending variance: Actual overhead - Budgeted overhead
   • Volume variance: Applied overhead - Budgeted overhead

Expected Result: Detailed variance analysis with root cause identification.

3. Inventory Valuation Process

Physical Inventory Count:

1. Go to Inventory → Physical Count
2. Generate count sheets by location
3. Execute physical counting
4. Enter count results
5. Process count adjustments

Inventory Valuation:

1. Raw Materials (FIFO method):

   • Calculate weighted average cost
   • Apply FIFO cost layers
   • Adjust for obsolescence

2. Work in Process:

   • Material costs issued
   • Labor costs applied
   • Overhead allocation

3. Finished Goods (Standard cost):

   • Standard cost per unit
   • Quantity on hand
   • Obsolescence reserves

Valuation Reports:

• Inventory aging analysis
• Slow-moving inventory report
• Obsolescence assessment
• Cost trend analysis

Expected Result: Accurate inventory valuation for financial reporting.

4. Cost Reporting and Analysis

Product Profitability Analysis:

1. Navigate to Reports → Cost Analysis
2. Generate Product Profitability Report:
   • Sales revenue by product
   • Standard cost of goods sold
   • Gross margin analysis
   • Volume impact analysis

Manufacturing Cost Reports:

1. Cost of Production Report:

   • Total costs by period
   • Cost per unit trends
   • Efficiency metrics

2. Variance Summary Report:

   • Material, labor, overhead variances
   • Variance trends over time
   • Exception analysis

Management Dashboards:

• Real-time cost metrics
• Key performance indicators
• Budget vs actual comparison
• Profitability by product line

Cost Optimization Recommendations:

• Identify cost reduction opportunities
• Process improvement suggestions
• Supplier cost negotiations
• Design for manufacturability feedback

Expected Result: Comprehensive cost insights for management decision-making.

1. Subcontracting Setup

Vendor Configuration:

1. Navigate to Purchasing → Vendor Master
2. Create/update vendor SMT-Services-Ltd
3. Set vendor type to Subcontractor
4. Configure capabilities:
   • SMT assembly services
   • Testing capabilities
   • Quality certifications
   • Capacity information

Service Item Setup:

1. Go to Inventory → Item Master
2. Create service item SMT-ASSEMBLY-SERVICE
3. Set item type to Service
4. Define cost center allocation
5. Set standard service rate

BOM Configuration:

1. Update BOM for AC-SENSOR-001
2. Modify Operation 10 (SMT Assembly):
   • Set operation type to Subcontracted
   • Assign subcontractor vendor
   • Define material consumption at vendor

Expected Result: Complete subcontracting framework configured.

2. Create Subcontracting Purchase Order

Generate Subcontracting PO:

1. Navigate to Manufacturing → Subcontract Orders
2. Click Create from Work Order
3. Select work order for AC-SENSOR-001
4. System generates PO with:
   • Service line: SMT assembly service
   • Material lines: Components to be supplied
   • Delivery schedule
   • Quality requirements

PO Details Configuration:

1. Service Line:

   • Quantity: 100 units
   • Rate: $2.50 per unit
   • Delivery date: Next Wednesday

2. Material Lines (to be supplied):

   • PCB boards: 100 pieces
   • SMT components: Per BOM requirements
   • Delivery location: Vendor facility

3. Terms and Conditions:

   • Quality specifications
   • Inspection requirements
   • Payment terms
   • Return material procedures

Expected Result: Comprehensive subcontracting purchase order ready for approval.

3. Material Transfer to Subcontractor

Prepare Material Shipment:

1. Navigate to Inventory → Material Transfer
2. Create transfer order to vendor location
3. Include all materials per PO:
   • Verify quantities match requirements
   • Check quality status of materials
   • Generate packing lists

Execute Material Issue:

1. Pick Materials:

   • Generate pick list
   • Reserve inventory
   • Process physical pick

2. Quality Check:

   • Inspect materials before shipment
   • Verify part numbers and quantities
   • Check for damage

3. Ship to Vendor:

   • Create shipping documents
   • Track shipment status
   • Confirm vendor receipt

Inventory Impact:

• Materials moved to “Consignment at Vendor” location
• Maintain ownership until consumed
• Track inventory at vendor facility

Expected Result: Materials delivered to subcontractor with full traceability.

4. Receiving and Quality Control

Receive Subcontracted Goods:

1. Navigate to Purchasing → Goods Receipt
2. Select subcontracting PO
3. Record receipt details:
   • Quantity received
   • Delivery date and time
   • Vendor delivery note reference
   • Initial visual inspection

Quality Inspection:

1. Incoming Inspection:

   • Create inspection order
   • Execute quality tests per plan
   • Record inspection results
   • Make accept/reject decision

2. Service Verification:

   • Verify work performed per specifications
   • Check assembly quality
   • Validate test results from vendor
   • Document any discrepancies

Process Completion:

1. Accept Goods:

   • Move to appropriate inventory location
   • Update work order progress
   • Trigger next operation

2. Invoice Processing:

   • Match invoice to PO and receipt
   • Verify service charges
   • Process payment

3. Cost Allocation:

   • Allocate service costs to work order
   • Update product standard costs
   • Record actual vs budget variance

Expected Result: Quality subcontracted parts received and ready for next operation.

Production Performance

Key Metrics to Track:

• Overall Equipment Effectiveness (OEE)

  • Availability × Performance × Quality
  • Target: >85% for critical equipment

• On-Time Delivery (OTD)

  • Orders delivered on promised date
  • Target: >95% for customer satisfaction

• Production Throughput

  • Units produced per hour/day
  • Track trends and improvements

• Capacity Utilization

  • Actual production vs planned capacity
  • Identify bottlenecks and constraints

Dashboard Access: Manufacturing → Analytics → Production Dashboard

Quality Performance

Quality Metrics:

• First Pass Yield (FPY)

  • Units passing first time / Total units
  • Target: >98% for manufacturing excellence

• Defect Rate

  • Defects per million opportunities
  • Track by product and process

• Customer Returns

  • Return rate and root causes
  • Cost of quality analysis

• Supplier Quality

  • Incoming inspection results
  • Supplier performance scorecards

Access: Quality → Analytics → Quality Dashboard

Cost Analytics

Cost Performance:

• Cost Variance Analysis

  • Material, labor, overhead variances
  • Monthly trending and analysis

• Product Profitability

  • Gross margin by product
  • Product mix optimization

• Inventory Turns

  • Inventory turnover ratio
  • Working capital efficiency

• Cost per Unit Trends

  • Unit cost changes over time
  • Cost reduction initiatives tracking

Access: Accounting → Analytics → Cost Dashboard

Operational Efficiency

Efficiency Metrics:

• Labor Efficiency

  • Standard hours vs actual hours
  • Productivity improvements

• Machine Utilization

  • Equipment uptime and usage
  • Maintenance effectiveness

• Material Utilization

  • Material yield percentages
  • Waste reduction tracking

• Lead Time Performance

  • Manufacturing lead times
  • Order fulfillment speed

Access: Manufacturing → Analytics → Efficiency Dashboard

Phase 1: Foundation (Weeks 1-4)

Core Setup:

• Item master data creation
• BOM development and validation
• Work center configuration
• Basic routing setup
• Initial user training

Expected Outcomes:

• Production orders can be created
• Basic material planning functional
• Shop floor tracking operational

Phase 2: Enhancement (Weeks 5-8)

Advanced Features:

• MRP implementation
• Quality control procedures
• Cost accounting setup
• Subcontracting workflows
• Advanced reporting

Expected Outcomes:

• Automated planning operational
• Quality processes integrated
• Complete cost visibility

Phase 3: Optimization (Weeks 9-12)

Performance Improvement:

• KPI dashboard deployment
• Process optimization
• Automation implementation
• Integration with other modules
• Advanced analytics

Expected Outcomes:

• Optimized manufacturing operations
• Real-time visibility and control
• Continuous improvement process

Ongoing Operations

Continuous Improvement:

• Regular performance reviews
• Process optimization initiatives
• Technology upgrades
• User training and development
• Best practice sharing

Success Metrics:

• Improved operational efficiency
• Reduced manufacturing costs
• Enhanced product quality
• Better customer satisfaction