Assembly and production reports

Usystems provides several built-in reports to help you track production builds, monitor material usage, and analyze production costs. These reports give you visibility into which items you are building, the components you are consuming, and the cost of production.

Before you start

• You have permission to view production data and reports (typically granted to manufacturing, production, or supervisory staff).
• You have created at least one build or production run (see "Creating and completing a build" for details).
• You understand basic manufacturing concepts: bill of materials (BOM), build quantity, finished goods, and production cost.

The main production reports

BOM / Assembly Structure

The BOM / Assembly Structure report shows the active bill of materials (recipe) for each finished product in your system.

Go to Reports → Production Reports and choose BOM / Assembly Structure.

Open in Usystems

For each BOM you will see:

• Product — The finished product code and name.
• BOM Code — The identifier for this bill of materials (if assigned).
• Components — A list of all raw materials and parts that go into the finished product, including:
  • Component code and name.
  • Quantity required per finished unit.
  • Unit of measure (pieces, kg, meters, etc.).
• Total BOM Cost — The sum of all component costs, which represents the material cost of one finished unit.
• Status — Whether the BOM is active, draft, or obsolete.
• Effective Date Range — When this BOM version is valid (if the BOM is versioned).

This report is useful for:

• Verifying that all components are correctly defined in a recipe.
• Reviewing component quantities before starting a production run.
• Understanding the material cost baseline for a finished product.
• Comparing BOM versions over time if you have multiple revisions.

Production / Build History

The Production / Build History report tracks every build (production order) you have created, showing quantities produced, actual cost, and completion status.

Go to Reports → Production Reports and choose Production / Build History.

Open in Usystems

For each build you will see:

• Build Code — The identifier for this production order (e.g., BUILD-001).
• Product — The finished product that was built.
• Quantity Planned — The number of units you intended to produce.
• Quantity Produced — The actual number of units completed (may differ from planned if shortages or rework occurred).
• Status — The build status (Pending, In Progress, Completed, or Cancelled).
• Build Date — When the build was created or started.
• Completion Date — When the build was marked as complete.
• Production Cost — The total actual cost of materials used in this build (based on component cost at the time of production).
• Cost Per Unit — Average cost per unit produced (total cost ÷ quantity produced).

This report is useful for:

• Tracking which products you have manufactured and when.
• Reviewing production volume over a period.
• Comparing planned vs. actual quantity produced.
• Analyzing actual production cost and identifying cost trends.
• Verifying that completed builds are reflected in finished goods inventory.

Production Material Consumption

The Production Material Consumption report shows all raw materials and components that were issued or consumed during production builds.

Go to Reports → Production Reports and choose Production Material Consumption.

Open in Usystems

For each material line you will see:

• Build Code — Which production order consumed this material.
• Component — The raw material or part code and name.
• Quantity Issued — How many units of the component were deducted from inventory.
• Unit Cost — The cost per unit of the component (at the time of issue).
• Total Cost — The extended cost (quantity × unit cost).
• Issue Date — When the material was consumed.

This report is useful for:

• Auditing which components were used in each build.
• Identifying materials with high consumption or cost.
• Verifying that material deductions match your physical inventory counts.
• Tracking material waste or scrap during production.
• Reconciling component inventory against build records.

Production WIP and Scrap

The Production WIP and Scrap report summarizes work-in-progress (WIP) inventory and scrap activity for unfinished or discarded production.

Go to Reports → Production Reports and choose Production WIP and Scrap.

Open in Usystems

For each item you will see:

• Build Code — The production order.
• Product — The item being manufactured.
• WIP Quantity — Units still in production (not yet marked complete).
• WIP Cost — The accumulated production cost for unfinished units.
• Scrap Quantity — Units that were discarded or deemed unusable during production.
• Scrap Cost — The cost of materials in scrap items.
• Variance — The difference between actual cost and standard cost (useful for identifying efficiency issues).

This report is useful for:

• Monitoring builds that are not yet complete (work-in-progress).
• Tracking production waste and scrap disposal.
• Identifying cost overruns or efficiency variances in production.
• Assessing the financial impact of incomplete or failed builds.
• Planning production adjustments based on scrap levels.

How to use these reports

1. Choose a report from the Reports menu based on what you want to analyze (cost, build status, materials, etc.).

2. Apply filters (if available) such as:

   • Date range (e.g., builds completed between June 1 and June 30).
   • Product or product category (to focus on a specific item).
   • Build status (completed, pending, etc.).

3. Review the data in the table or grid. Look for:

   • Any missing or unexpected entries.
   • Cost trends over time.
   • Variances between planned and actual quantities or costs.

4. Export or print the report (if needed) by using the report export option to save as PDF or Excel.

5. Cross-check with accounting by comparing production costs in these reports with your general ledger to ensure all builds have been correctly posted.

Accounting impact

The data in production reports flows into your accounting system as follows:

• Raw materials consumed are removed from inventory and posted to the Cost of Goods Manufactured.
• Finished goods produced are added to finished goods inventory at their production cost.
• Scrap and waste may be posted to a scrap or waste expense account (depending on your setup).
• Production variance (the difference between standard and actual cost) is tracked for management analysis.

All build completions are automatically synchronized with the general ledger, so your inventory and cost of goods sold accounts remain accurate.

Tips & common mistakes

• Run the BOM report before starting production. Verify that all components and quantities are correct before you create a build and commit inventory.
• Monitor cost per unit trends. If actual cost per unit rises significantly, investigate whether component costs have changed or if there is production inefficiency.
• Reconcile Material Consumption with your physical counts. If your on-hand inventory does not match the system after a build, check the Material Consumption report to verify that all issues were recorded.
• Check WIP builds regularly. Builds stuck in WIP status for long periods tie up cash and may indicate production delays or data entry errors.
• Link scrap back to quality issues. High scrap rates may signal supplier quality problems or production training gaps; use the Scrap report to flag issues for management review.