Production records in the Flexi system consist of several steps. Their foundation is the bill of materials (BOM), i.e. the product structure.
A product can consist of individual items (material) or of semi-finished products (which, for Flexi, are also a product - they have a bill of materials set up). Semi-finished products need to be manufactured separately first.
Below, we'll show you an example of working with a bill of materials and the production process in ABRA Flexi.
⚠️ The bill of materials feature is available from the Premium license tier. In lower tiers, you won't find the Bill of Materials tab in the price list.
Initial Steps
In the menu Business Partners – Company Addresses, set up your supplier and customer.
In the menu Goods – Warehouse List, create warehouses (e.g. Finished Products Warehouse, Semi-Finished Products Warehouse, Materials Warehouse) and on the Management tab, check the flag Automatically add new goods to this warehouse.
For better clarity in the price list, we recommend creating a tree structure. For example, we recommend dividing it into: products, semi-finished products, and materials. You'll find instructions in the tree structure section of the price list in the documentation.
Create goods and materials groups in the menu Goods – Goods and Materials Groups; for example, create 3 groups - products, semi-finished products, materials. We'll use this group primarily in Warehouse Mapping.
In the menu Goods – Warehouse Mapping, define the mapping for the bill of materials breakdown. You'll find instructions for setting up warehouse mapping here. If you have multiple cost centers, you can map a warehouse for a specific cost center.
Now all that's left is to define the product itself in the price list. In our case, this will be a mountain bike.
Price List
Enter the following items into the price list as Inventory items (other fields are up to you):
Materials Record
Frame: Goods Group field = Material, Purchase Price = CZK 3,500;
Handlebars: Goods Group field = Material, Purchase Price = CZK 2,000;
Derailleur: Goods Group field = Material, Purchase Price = CZK 1,200;
Chainring - Goods Group field = Material, Purchase Price = CZK 600;
Spokes - Goods Group field = Material, Purchase Price = CZK 20;
Rim - Goods Group field = Material, Purchase Price = CZK 150.
Semi-Finished Products Record
Rear wheel: Goods Group = Semi-Finished Product;
Front wheel: Goods Group = Semi-Finished Product;
Products Record
Mountain bike: Goods Group (Product).
Now sort the individual items into the price list tree and set up warehouse mapping. Create 3 records in it - one for each goods group and warehouse. For example, Goods Group - Material; Preselected Warehouse - Material (and so on).
Once you have the above set up, we can move on to setting up the bill of materials.
Bill of Materials
For each semi-finished product and product, you need to fill in the bill of materials. It's used to set the components that the given product will consist of (in our case, the mountain bike). The bill of materials setup is not dependent on the warehouse. You can access it via the menu Goods – Price List – Bill of Materials tab.
Setting Up Semi-Finished Products
In the Price List, create the semi-finished products "Front wheel" and "Rear wheel".
Go to the Bill of Materials tab and use the Create button to set up the root.
Click on the root and gradually add individual items (materials) that the semi-finished product will consist of. In our case, both the front and rear wheel consist of: Rim x1; Spokes x32; Hub x1.
Setting Up the Product
In the Price List, create the product "Mountain bike".
Go to the Bill of Materials tab and use the Create button to set up the root.
Click on the root and gradually add individual items (materials) that the product will consist of. In our case, this consists of: Frame x1; Handlebars x1; Derailleur x1; Chainring x1; Front wheel x1; Rear wheel x1.
Warehouse Document Types
Create two types of warehouse documents according to the example below.
Production Issue
The key thing here is only the movement type setting - other fields are up to you.
Production Receipt
The key thing here is setting the movement type, movement type detail - Product Receipt (this ensures the subsequent issuing of the material set in the product's bill of materials) and the production document type - specify the previous type, Production Issue.
Received Orders
Companies order products from you, e.g. 50 mountain bikes.
Go to the menu Sales – Received Orders. Create an order from the relevant customer for 50 mountain bikes.
On the just-created received order, use the Create Issued Order service. This will create an issued order for 50 mountain bikes.
Issued Orders
First, you need to create an issued order type - e.g. Production Order. In its settings, specify Goods Receipt Type - Production Receipt.
On the newly created issued order, change the document type to Production Order and use the Create Order for Production service. This will order all the necessary material (including material needed for producing the semi-finished products).
Receiving the Product and Semi-Finished Products into the Warehouse (Production)
First, you need to receive the material into the warehouse. On the previously created Issued Order for Production, you can do this via Services > Create Goods Receipt, which will stock the material.
Next, you need to produce the semi-finished products. In our case, these are the Front wheel and Rear wheel. So we'll create a goods receipt with the document type Production - Receipt and enter 50 pieces of both semi-finished products.
A goods issue for the relevant material - hubs, rims, and spokes - will be created automatically.
Once we have the semi-finished products manufactured, we can go back to the original issued order - the one for 50 mountain bikes. In the services on this order, select the Create Goods Receipt option.
Once this goods receipt is saved, 50 mountain bikes will be received into the warehouse. This will ensure that all the material listed in its bill of materials is issued from stock. The material goods issue will again be created automatically.
However, if there isn't enough material in the warehouse specified in the warehouse mapping, an error message will appear with a detailed description of how much material is missing in which warehouse.
Once the relevant products are in stock (produced), we can return to the received order and fulfill it.
On the received order, use one of the required services - either Create Invoice or Create Goods Issue.