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Add Assemblies & Sub-Assemblies

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The Add Assembly page enables you to create a product assembly using component products based on a Bill Of Materials.

  • An assembled product is made up of one or more components or a single Bill of Material. 
  • You can create and edit assemblies for a product based on its Bill of Materials.
  • The finished goods being produced must already have an existing product in the product list.
  • When you complete an assembly, the components are taken out of the available stock and the finished product is assembled.
If you have an existing Bill of Materials for a product, the details will be automatically completed when you enter the quantity to be assembled. You can edit the values if required. - When entering an assembled quantity the quantities of the components will be updated based on the quantities entered in the Bill of Materials. 
 

Creating an Assembly

  1. Go to Production | Assemblies | Add Assembly. Complete/select the following details:

  2. You can specify the Source Warehouse and Destination Warehouse.
  • Source Warehouse: The warehouse from which the component products are taken from to build the assembled product and the stock on hand will decrease.
  • Destination Warehouse: The warehouse where the assembled finished product will be added and stock on hand will increase.
  • Product Code & Description: The product you want to assemble. You must have an associated Bill of Materials created for the product.
  • Assembled Quantity: The quantity you want to assemble. Once you have entered the Assembled Quantity, you can adjust the quantities used and remove lines where necessary to better reflect what was used in the assembly. 
  • Available Quantity: Displays the total amount of finished goods you can produce based on the available quantity for the component products.
  1. On the Assembly Lines, the component products from the Bill Of Materials will be displayed. If you want to edit or add additional component products:
  • Component Product: Select components by typing the code or description of the product or use the magnifying glass to search. 
  • Quantity: Specify the quantity you want to assemble. After you enter a value to this field, your components and their quantities will be loaded from the respective BOM. If you want the Assembled Quantity after that, you will be prompted to cascade that change to the component numbers through a pop-up screen. 
  • Wastage Qty: When you assemble your finished goods, the wastage quantity and assembly quantity will be removed from your component products stock on hand count. The value of both the quantity and wastage quantity of the component is then assigned to the finished product for all component products on a Bill of Materials.
  • If you add a Never Diminishing product, note the following points:
    • If you have an accounting provider integration with Unleashed, the Expense Account drop-down list will be available ONLY for Never Diminishing products.
    • The Expense Account field values are retrieved from the linked accounts in the Accounting provider. Ensure that you select the correct account.
    • When you complete an assembly or disassembly, a journal will be passed to the integrated accounting provider.
    • The Unit Cost is displayed and you can edit the cost if required.
  1. On the Supplier Costs tab, you can add any required supplier costs:
  • Assembly Costs is only available on specific subscription plans. 
  • Type or select the supplier.
  • You can add the cost, and edit the TaxableCost DateReference, and Comments fields.
  • The Currency and Tax fields are automatically retrieved.
  • You can edit the exchange. It defaults to the Currency Rate in Unleashed.
  • Click Add.
  1. Click Save or Complete

Managing a Sub-Assembly

If you have a product that is made up of components which are also assembled (and you already have the Bill of Materials set up), you can automatically create the next level from inside the original assembly. Please see the example below where the product "24pack" is created using four units of the 6pack.     

  1. Go to Production | Assemblies | Add Assembly

If the component product(s) are assembled, you'll have the option to create the next level of the assembly workflow using the blue plus button shown above. When you click this button, you'll see the dialogue box below.

Unleashed will calculate the "Can Assemble" quantity and suggest the "Assembled Quantity" based on how much you need to assemble to be able to fulfill the main assembly.   
  1. After clicking the "Create Sub-Assembly" button, the blue plus buttonwill change into an orange exclamation mark.
  2. When you click on it, you will be taken to the next stage where you will be able to manage that assembly. If you want to view the Sub-Assembly or complete it, you can do this from the upper level by using the action cog, shown below. 

This structure will repeat itself so long as new Sub-Assemblies continue to be created. 
  1. When finished with creating multiple assemblies, click "Save" (to save the transaction without processing it) or "Complete" (when ready to complete the transaction(s). 

Please keep in mind that deleting a Sub-Assembly will not impact the Parent transaction and vice-versa. 

A parent assembly cannot be completed until all Sub-Assemblies have been completed.

Assembly Tutorial


If you have Batch Number Tracking enabled 

Assemble a new batch

This function allows you to assemble new products and link a batch number and expiry date to it. It works on any assembly (assembled product has to be batch tracked) and allows you to add: 

When an assembly is completed, a record is created for the new batch. The Quantity, Expiry Date, Batch Number and other ingredients are saved. 

Batch Numbers must be unique for the product. 

Batch Assembly diagram 

This diagram illustrates how Unleashed can monitor a component or ingredient from your Suppliers right through to the Customers.

 

Assemble a product with batch tracked components

If you want an assembly to be built with a:

When these are enabled, then a new column appears called Batch Number. This contains  - and + collapsible function where you can enter in the required quantity to assemble.

 

You can use the Filter Batch Number field to search for batch numbers. Alternatively, you can use the Select Oldest link to instantly select the oldest batch available. Once you have entered in your specified amount, you can save or complete accordingly (by clicking on Save or Complete buttons). 


If you have Serialized Products 

Assemble Serialized Products
Assemble a serialized component product

Assemble Serialized Products

This function allows you to assemble new products and link serial numbers to it. It works on any Assembly and allows you to: 

Ensure that all serial numbers are assigned, otherwise it cannot complete.
This function is ideal for warranty purposes because when you assemble a kit or a number of kits, you can save the serial number for each of those kits. That serial number can then be used in future for warranty purposes.

When the Assembly is completed, a record is created. The Quantity, Serial Number and other ingredients are saved. See Assemble a serialized tracked component product for more information.

Assemble a serialized tracked component product

If you want an Assembly to be built with a dedicated serial number, or have a Component product with different serial numbers attached, then you need to have both the following selected.

Once these checkboxes are enabled, a new column appears called 'Serial Number.'  This contains  - and + collapsible function where you can assign and enter in the specified serial numbers you want attached to the Assembly.


  • Assemble a new batch
  • Batch Assembly diagram
  • Assemble a batch tracked component product
  • Batch Number (mandatory field)
  • Expiry Date (optional field) 
  • As you receive a component/ingredient, you record its batch number.
  • The batch is tracked through the assembly process, enabling you to monitor every step along the way. For example, in the food and beverage industry, if you have an affected batch that you want to recall, then having the ability to track all of your components, allows you to have full control of the components used. In this instance, the customer will be able to see that the #h4 component  that was part of the #beer4 assembly is affected, the business can then contact the suppliers and customers accordingly and recall the affected stock.
  • dedicated batch number, and
  • have a Component product from different batches, then you need to have both the Batch Tracked checkbox ticked and also the Component checkbox ticked on the Product you want to use.
  • Add Serial Numbers on the final product
    This can be easily achieved by:
  1. Tagging the product as 'Serialized' (on the Add Product page)
  2. From the Assemblies page you can apply a serial number to it, this can be done from the Serial Number tab on the Assemblies page.
  3. Use the Items field to add new Serial Numbers or the Filter Serial Numbers field provided to search for existing serial numbers and select accordingly.
  4. Click Add Serial and then Complete to complete your Assembly.
  • All of your Components can also have Serial Numbers linked to your final product. 
    This is also ideal for warranty purposes.  For example, you might have a warranty for an entire pack but you may only require one component item for the warranty, this function allows you to locate a component —via its serial number— item and then contact the supplier.
  • Serialized checkbox ticked, and the
  • Component checkbox ticked on the Product you want to use.
  1. If you have selected your finished Product, Assembly Quantity and are happy with the Bill of Materials for this production, simply click Complete at the top of your page, and your desired quantity is produced. If you wish to Delete, Print or Save (park) this assembly you can use the buttons at the bottom right of the page.

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