Machine Production
Some machines in construction and industrial operations produce output materials that are subsequently stocked and issued to projects. Examples include batching plants producing concrete, crushers producing aggregates, and fabrication shops producing structural components. The Machine Production feature in JobNext links machine usage to material output, enabling accurate costing and inventory tracking.
Production is managed from the machine details screen: Equipment > Machines > [Select Machine] > Production tab. BOM setup is done through SCM > Material Master > [Select Material] > BOM tab.
Production Workflow
Step 1: Set Up Bill of Materials (BOM)
Before a machine can produce output, you must define the Bill of Materials (BOM) for the output material. The BOM specifies what input materials are consumed per unit of output produced.
BOM Configuration Steps
- Navigate to SCM > Material Master
- Search for and open the output material that the machine will produce (e.g., "Ready Mix Concrete M25")
- Click the BOM tab in the material detail screen
- Click Add Input Material to define each raw material consumed in production
- For each input material, specify:
- Material Code — The input material from the Material Master
- Quantity — The amount consumed per one unit of output
- UOM — The unit of measurement (KGS, CBM, LTR, etc.)
- Click Save to store the BOM configuration
BOM Example
To produce 1 CBM of Ready Mix Concrete M25, the BOM might specify:
| Input Material | Quantity | UOM |
|---|---|---|
| Cement (OPC 43 Grade) | 320 | KGS |
| Coarse Aggregate (20mm) | 0.60 | CBM |
| Fine Aggregate (Sand) | 0.45 | CBM |
| Water | 160 | LTR |
| Admixture (Plasticizer) | 2.5 | LTR |
Both the output material and all input materials must already exist in the Material Master. Ensure that input materials have the correct UOM defined and are available in stock at the Job where production will occur.
Step 2: Log Machine Production
Once the BOM is configured, log production each time the machine produces output:
- Navigate to Equipment > Machines
- Open the machine that performed the production (e.g., Batching Plant)
- Go to the Production tab
- Click Add Production
- Fill in the production details:
| Field | Description | Required |
|---|---|---|
| Output Material | The material being produced (must have BOM configured) | Yes |
| Quantity Produced | The amount of output material produced | Yes |
| UOM | Unit of measurement (auto-populated from material) | Yes |
| Production Date | The date production occurred | Yes |
| Target Job | The Job where the output material will be stocked | Yes |
Step 3: Transfer Production to Job Stock
After logging production, the output material must be transferred to the target Job's stock to make it available for consumption. This step:
- Creates a stock lot at the target Job for the produced material
- Updates inventory records with the new stock quantity
- Deducts the BOM-calculated input material quantities from the Job's existing stock
- Creates stock transaction records for audit traceability
When production is transferred to Job stock, the system automatically calculates the input material consumption based on the BOM and the quantity produced. For example, producing 10 CBM of concrete with the BOM above would deduct 3,200 KGS of cement, 6 CBM of coarse aggregate, 4.5 CBM of sand, 1,600 LTR of water, and 25 LTR of admixture from the Job's inventory.
Step 4: Issue Produced Material
Once the produced material is in Job stock, it can be issued through the standard SCM > Material Issue workflow for use on the project. This follows the same process as any other material issue:
- Navigate to SCM > Material Issue
- Select the Job and the produced material
- Enter the issue quantity
- Submit for approval
Common Use Cases
| Machine Type | Output Material | Typical Input Materials |
|---|---|---|
| Batching Plant | Ready Mix Concrete (various grades) | Cement, aggregates, sand, water, admixtures |
| Crusher | Crushed aggregate (various sizes) | Raw rock / boulders |
| Hot Mix Plant | Bituminous mix / asphalt | Aggregate, bitumen, filler, fuel |
| Fabrication Shop | Fabricated steel components | Steel plates, sections, welding consumables |
| Block Making Machine | Concrete blocks / pavers | Cement, sand, aggregates, pigments |
Costing Impact
Machine production enables accurate tracking of the cost per unit of output. The cost of produced material is derived from:
- Input material cost — Weighted average cost of all BOM materials consumed
- Machine operating cost — Depreciation, fuel, maintenance allocated via percentage allocation
- Labour cost — Operator wages allocated to the machine's Job
This enables project managers to compare the cost of self-produced materials against market rates for procurement decisions.
Log production daily and transfer to stock promptly. Delayed transfers can create discrepancies between physical stock (which exists on site) and system stock (which has not been updated). Regular reconciliation ensures accurate inventory and costing.
Frequently Asked Questions
Can a machine produce multiple output materials?
Yes. Each output material has its own BOM configuration. You can log production for different materials from the same machine on different dates or the same date.
What happens if input materials are not in stock?
The transfer to Job stock will fail if insufficient input material is available. Ensure all BOM materials are stocked at the Job before transferring production. You may need to procure or transfer stock from another Job first.
Can I adjust a production log after it is transferred?
Once production has been transferred to stock, the log cannot be edited. If a correction is needed, log a new production entry with the adjusted quantity, or use Stock Adjustment to correct inventory.