Production tracking in the Flexi system consists of several steps. Its foundation is the bill of materials — the product structure.

A product can consist of individual items (materials) or semi-finished products (which are also treated as products in Flexi — they have their own bill of materials). Semi-finished products must first be manufactured separately.

Below, we will walk through an example of working with the bill of materials and the production process in ABRA Flexi.

Initial Steps

In the menu Business Partners – Company Addresses, create your suppliers and customers.
In the menu Goods – Warehouse List, create your warehouses (e.g., Finished Goods Warehouse; Semi-Finished Goods Warehouse; Materials Warehouse) and on the Administration tab, check the option Automatically add new items to this warehouse.
For better clarity in the price list, we recommend creating a tree structure for improved organization. We suggest dividing it into: finished products, semi-finished products, and materials. Instructions can be found in the price list tree structure section of the documentation.
Create goods and material groups in the menu Goods – Goods and Material Groups; create, for example, 3 groups — finished products, semi-finished products, materials. Groups are used primarily in Warehouse Mapping.
In the menu Goods – Warehouse Mapping, define the mapping for bill of materials explosion. Instructions for setting up warehouse mapping can be found here. If you have multiple cost centers, you can map a warehouse to a specific cost center.
The remaining step is to define the product itself in the price list. In our example, this will be a mountain bike.

Price List

Enter the following items in the price list as Stock items (other details are at your discretion):

Material Records

Frame: Goods Group field = Material, Purchase Price = CZK 3,500;
Handlebars: Goods Group field = Material, Purchase Price = CZK 2,000;
Rear 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 Product Records

Rear Wheel: Goods Group = Semi-Finished Product;
Front Wheel: Goods Group = Semi-Finished Product;

Finished Product Records

Mountain Bike: Goods Group (Finished Product).

Now sort the individual items into the price list tree and configure warehouse mapping. Create 3 records there — one for each goods group and warehouse. For example: Goods Group - Material; Default Warehouse - Materials (and so on).

Once the above configuration is in place, you can proceed to set up the bill of materials.

Bill of Materials

For each semi-finished product and finished product, you need to fill in the bill of materials. It is used to define the components that the product will consist of (in our case, a mountain bike). The bill of materials configuration is not warehouse-dependent. You can access it via the menu Goods – Price List – Bill of Materials tab.

Creating 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 create the root node.
Click on the root node and gradually add the individual items (materials) that the semi-finished product will consist of. In our case, both the front and rear wheels include: Rim 1x; Spokes 32x; Hub 1x.

Creating the Finished Product

In the Price List, create the finished product "Mountain Bike".
Go to the Bill of Materials tab and use the Create button to create the root node.
Click on the root node and gradually add the individual items (materials) that the finished product will consist of. In our case, the mountain bike includes: Frame 1x; Handlebars 1x; Rear Derailleur 1x; Chainring 1x; Front Wheel 1x; Rear Wheel 1x.

Warehouse Document Types

Create two warehouse document types following the examples below.

Production Issue

The only critical setting here is the movement type; all other details are at your discretion.

Production Receipt

The critical settings here are the movement type, the movement type detail — Finished Goods Receipt (this triggers the automatic issue of materials defined in the product's bill of materials) — and the production document type — set this to the previously created Production Issue type.

Sales Orders

Companies place orders with you for finished products — for example, 50 mountain bikes.

Go to the menu Sales – Sales Orders. Create an order from the relevant customer for 50 mountain bikes.

From the newly created sales order, use the Create Purchase Order action. This will generate a purchase order for 50 mountain bikes.

Purchase Orders

First, you need to create a purchase order type — for example, Production Order. In its settings, specify the Receipt Type - Production Receipt.

On the newly created purchase order, change the document type to Production Order and use the Create Manufacturing Order action. This will arrange the ordering of all required materials (including those needed for the production of semi-finished products).

Receiving Finished Products and Semi-Finished Products into Stock (Production)

First, you need to receive the materials into stock. From the previously created manufacturing purchase order, you can use Services > Create Receipt to stock the materials.

Next, the semi-finished products must be manufactured. In our case, these are the Front Wheel and Rear Wheel. Create a receipt with the document type Production Receipt and enter 50 units of each semi-finished product.

An issue document for the corresponding materials — hubs, rims, and spokes — will be created automatically.

Once the semi-finished products have been manufactured, you can return to the original purchase order — the one for 50 mountain bikes. From the actions available on that order, select Create Receipt.

When this receipt is saved, 50 mountain bikes will be received into stock. This will trigger the automatic issue of all materials listed in the product's bill of materials. The material issue document will again be created automatically.

However, if there is insufficient material in the warehouse specified in the warehouse mapping, an error message will be displayed with a detailed description of how much material is missing and from which warehouse.