Production runs out of materials
Solution: Review the approved material list against planned output before release.
Expected result: Shortages are identified earlier.
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MALUONE ERP MODULES
Manufacturing
Explore the production flow from required materials to finished output and its cost.
For production planners, supervisors and cost accountants.
Request a Manufacturing Demo
Problems your team needs to solve
Finished stock is overstated
Solution: Record actual completed quantities separately from planned output.
Expected result: Available stock reflects goods actually produced.
Costs do not explain the work performed
Solution: Record additional material use and rework reasons.
Expected result: Cost reviews have supporting evidence.
Understand the workflow
Plan → Materials → Production → Actual output → Cost review
Materials and routing
Discuss bills of materials and the steps needed to make your products.
Production orders
Follow planned production, materials issued and finished goods received.
Production costing
Review how material usage and production output contribute to product costs.
Common mistakes to avoid
- Using an outdated bill of materials.
Prevention: Review the approved material list before releasing production.
- Omitting scrap and rework.
Prevention: Record scrap, additional usage and rework reasons as they occur.
- Counting unfinished goods as completed output.
Prevention: Record actual finished quantities and keep remaining work separately visible.
Work through a complete example
Use these illustrative cases to evaluate the workflow with the demonstration team. Confirm the available screens, controls and configuration for your scope.
Follow the quantities and amounts
Plan 50 tables using four legs each: the planned requirement is 200 legs. Issue 204 legs, complete 48 tables, retain eight legs in unfinished work and record four damaged legs. The reconciliation is 192 legs in completed tables + 8 in unfinished work + 4 damaged = 204 issued. This example isolates one component; timber, labor and overhead require separate review.
Read the visual: compare each document or stage separately, then follow the reconciliation shown beside it.
Production order · 50 tables
48Completed
2In progress
Planned quantity is not finished stock
Reconcile 204 issued legs
192In finished tables
8Unfinished work
4Damaged
192 + 8 + 4 = 204 legs
Documents and team handovers
- 01
Approved production basis
Confirm the current bill of materials, units, routing and planned output before release.
- 02
Actual consumption
Record material issues, returns and extra usage with the production reference and reason.
- 03
Output and cost review
Separate finished output, remaining work and scrap; review how the agreed costing setup treats each.
When the normal process changes
Case 1: A material shortage stops work
Problem / consequence
The planned completion date no longer reflects actual readiness.
Correction / prevention
Review the shortage, remaining work and revised schedule; approve any material substitute before use.
Case 2: A batch requires rework
Problem / consequence
Extra material and effort disappear from the cost explanation.
Correction / prevention
Identify the affected batch, record additional usage and agree how rework is reviewed and costed.
Case 3: Part of the output fails inspection
Problem / consequence
Sales may promise goods that are not ready for release.
Correction / prevention
Separate completed quantities from accepted, held and rejected output; verify the required quality-release process in the demo.
Responsibilities, reports and controls
Planner and supervisor
Review approved specifications, material readiness and release responsibilities.
Production records
Capture actual issues, returns, output and reasons for deviations at the agreed stage.
Cost reviewer
Compare planned and actual usage, unfinished work and scrap. Confirm labor, overhead and work-in-progress allocation support.
Ask to see these cases in your demo
- Reconcile all 204 issued legs to completed output, unfinished work and damage.
- Show 48 completed tables and two still outstanding without overstating available stock.
- Demonstrate a specification change, extra issue and rejected-output case.
Agree the results and any limitations in the implementation scope before launch.
Prepare a useful demonstration
Bring these examples
Bring one bill of materials, a production order and actual consumption records.
Outputs to review
Discuss production progress, material usage and cost review requirements.
Confirm the scope
Confirm routing, work-in-progress, quality checks and cost allocation requirements before agreeing scope.