Some things are worth more than the sum of their parts! Not least in manufacturing, where the material costs of components are just the start of the true cost price of your shiny new finished goods. Extensive work, assembly, processing and labour goes into making something special – and this is where many businesses add their most value to the bottom line.

Process Routing is a special SQLWorks tool to help Production Managers organise, track and cost this essential part of the business workflow – ensuring finished goods are not only ‘made’ efficiently, but also priced appropriately.

If you have the Manufacturing module enabled, default Process Routes in SQLWorks can be assigned to the Bills of Material of any stock item, and these become the default process route for all new Works Orders instructing your team to make that item.

 

How Process Routing Works

Each Route is comprised of a series of process steps, each of which is given up to three attributes:

• Process Type – a ‘type’ of work, from a list defined by your business (mandatory.)
• Work Centre – a location where work happens, such as a piece of machinery or factory zone.
• Employee – a specific person, authorised to carry out that step in the process route.

 

 

To build a process route, simply drag and drop processes, work centres and employees onto a BOM’s process route, building up the chain of default steps needed to make the finished item. The route is automatically added to each new Works Order for that BOM.

(However, if an individual Works Order needs a different route on a specific Works Order, you can either ‘Change’ to a different pre-saved route with different steps, or ‘Edit’ the steps given to that specific Works Order using the default as your starting point, but adding your variations. Future Works Orders for this item will still use the BOM’s default process route, unless it is also updated.)

Each and every step on a Process Route can optionally contain detailed costings – based on labour and setup fees/time expired. In addition to setting your ‘Expected’ costs, you can use progress tracking to generate an ‘Actual’ cost for every step, and compare the two for an accurate picture of profitability.

Your factory may be full of active Works Orders, all taking different Process Routes on their journey to completion.

 

 

Key Benefits

There are several key benefits here:

 

 

Optional Extras

Depending on how you use Production Routing we’ve included extra controls to better fit the different kinds of business operations – and help you make better decisions. You can choose how to use all of these to get the most value from our software – or speak with our software development team, to introduce something entirely new.

Thanks for reading! For Production Routing and manufacturing software expertise, please contact our team today.

One of the questions we’re often asked surrounds the tricky issue of ‘negative’ stock quantities, and how SQLWorks can help warehousing operations balance flexibility with security.

By default, SQLWorks does not allow what some companies choose to call a ‘negative’ stock quantity. Ordinarily, the only stock that can be invoiced is the actual quantity of stock you hold, the act of invoicing moves it out of stock, and you cannot invoice a customer for stock you don’t have.

This is our recommended model, because it helps ensure business keep an accurate stock valuation and acts as natural protection against errors. While promises can be made to customers about stock owed, these remain only promises, and do not influence the company financials.

This model also makes intuitive sense to end-users: the ‘actual’ quantity will never be less than zero – reflecting the ‘actual’ amount a member of staff will find in a warehouse if they perform a stock check in person (either ‘some’ or ‘none’, but never a negative.)

However there are some instances where this principle runs into real-world difficulties. For example:

 

• In fast-paced business operations or large factory sites, manufactured goods may need to be physically loaded for dispatch before a shopfloor member of staff or office team at another location are able to confirm in the system that the new stock quantity is completed. The negative stock restriction can then become a bottleneck, as a lack of stock quantity seen in the system holds up the dispatch & invoicing process, and delays the delivery of stock that was otherwise ready on time.

• Production runs may not be exact – in some industries (such as printing) including and invoicing a small excess quantity or overrun of finished goods is typical: once again this can create a delay: where dispatch is held up by a tiny excess quantity that isn’t recognised in stock without some minor adjustments to data, and so can’t be invoiced in full.

• Large production runs may have special contract terms or non ad-hoc invoicing arrangements agreed, where invoicing might sometimes run ahead of the production of stock. For this, a company would need to be able to invoice stock they ‘owe’ to a customer, and takes an acceptable level of risk for doing so.

 

SQLWorks offers three different solutions to this kind of ‘negative stock’ problem:

 

Solution #1 – Enabling the Dispatch Note System

Enabling the Dispatch Note system adds one extra step in the progression from Order to Invoice: the Dispatch Note. Before an invoice, the user must issue a dispatch note to a customer, which can contain stock lines selected from multiple orders, even those without stock quantity available to be invoiced yet.

The quantity ‘dispatched but not invoiced’ is logged separately under ‘Pending’ until enough ‘Actual’ stock quantity is identified. Once the user is ready to invoice, the company must invoice from the available lines listed on existing dispatch notes.

This system doesn’t allow stock to go ‘negative’, since the user must always ‘book in’ the actual quantity to eventually cover what was dispatched, before they can finally invoice the customer – but it does allow the customer to receive their goods promptly, while maintaining traceability over what was shipped. The Dispatch Note system is a good solution where the underlying issue is the time delay.

The authority to issue dispatch notes can also be optionally granted to warehousing staff, and this system also works in tandem with the Dispatch Planner.

 

Solution #2 – ‘Flexibility Mode’

The first of two ‘Advance Batch’ modes, this option permits SQLWorks to create synthetic batches of stock it doesn’t have physically available. Doing so allows a company to invoice for stock they don’t have yet – albeit with some important safeguards in place.

Firstly, these artificial advance batches are tagged as such behind the scenes to prevent any errors being introduced into the stock valuation. Secondly, when new stock quantity then arrives in from completed manufacturing or purchase order deliveries, this artificial stock quantity figure is absorbed first – reflecting the fact that the real stock was already invoiced out.

Thirdly, in this mode SQLWorks is only allowed to create as much artificial stock quantity as is already listed on outstanding Purchase Orders or Works Orders. While the user is now allowed to send an invoice for stock that isn’t quite ‘to hand’ yet, there has to be a corresponding entry on the system indicating from where the business was expecting that stock to materialise.

For example: Advance and Adjusted stock quantities shown above, and a marker showing that stock batch 1016576 is an advance batch of x10 quantity that has been created by the system.

If you have Advance Batches turned on, you can use a quick filter under the Search bar to see all the items that have active advance batches (i.e those with negative stock that will use up future incoming quantity). If you print a stock valuation, advance batches will be treated as a ‘negative’ quantity for valuation purposes.

 

Solution #3 – ‘Unrestricted Mode’

The second of two ‘Advance Batch’ modes, this option permits SQLWorks to create batches of stock it doesn’t have physically available, with fewer restrictions.

Firstly, these artificial batches are tagged as such behind the scenes to prevent any errors being introduced into the stock valuation. Secondly, when new stock quantity then arrives in from completed manufacturing or purchase order deliveries, this artificial stock quantity figure is absorbed first – reflecting the fact that the real stock was already invoiced out.

However, in this mode there is no upper-limit enforced by the quantity outstanding on existing Works Order or Purchase Orders – allowing the company complete freedom to invoice irrespective of actual stock quantity, or even potential stock quantity.

Adopting this setting has important stock valuation and tax implications, so should only be used with great caution.

 

For ERP and stock control expertise, please contact our team today.

 

We’ve introduced some important quality assurance tools into SQLWorks – allowing users to formalise their quality tests at different points of the stock control lifecycle.

Quality tests can be customised extensively and introduced at various stages of your workflow – including when receiving goods in, when manufacturing finished goods, or whenever you choose to test a batch that is being held in stock. We’ve also included new abilities to generate, store and integrate Quality Certificates – which will be covered more fully in a future blog post.

 

 

About Quality Testing

Quality tests may be created as standalone templates for your business, and can be customised for a wide range of different metrics. Saved tests can be either advisory or pass/fail, and include numerical measurements, dates, text answers and more – as well as specifying a level of precision for measurement, up to five decimal places.

You can assign tests (or a subset) as the default to any stock item in the stock ledger, formalising the ‘official’ set of tests that apply to that item.

 

 

Quality Testing on Receipt

One of the most useful places to perform quality testing is at goods-in, at the point you receive inbound stock from a supplier. This can help check that you received what you purchase ordered, and that nothing is defective, damaged or missing.

To support this we’ve extended quality testing to the line-level of our purchase order receipt window – where the user can specify not only what goods were received, any variation to quantity, and those goods’ supplier lot number – but also save quality tests applicable to that line.

The correct tests for each line are automatically derived from that stock item’s defaults saved in the stock ledger, and results are automatically saved onto each new batch of stock that is created in the system when you receive the goods in – confirming that new stock has had its quality verified.

 

 

Quality Testing Manufacturing

Quality testing is also now available within Works Orders, helping you to verify that your finished goods have been manufactured correctly for sale.

Testing is listed under the ‘Inspection’ tab of a Works Order, and can be completed for each batch of finished goods that will be created by the works order.

Once again, the default tests are drawn directly from those specified on that stock item’s defaults.

 

 

Batch Quality Testing

Alternatively, a quality test may be completed for any given batch of stock via the ‘Batch Info’ tab of the stock ledger.

This is useful when you want to complete quality testing as a standalone process, test a batch at random, or look for something advised by a supplier (such as during a recall.)

SQLWorks gives businesses exceptional traceability over batches, the quality of your component stock, and the quality of your finished goods.

Backflushing is an alternative method of allocating components or materials to manufacturing, whereby stock is deducted only after production has been completed.

Backflushing makes it easier to work with quantities that would otherwise be highly impractical to ‘pick’ for use on Works Orders, and is a particularly useful technique when:

• • Components are too small or numerous to be ‘counted out’ in a sensible timeframe. (e.g.: screws, nuts, bolts, other low-cost parts used in volume.)
• • When materials are divisible, liquid, molten, gaseous, in lengths, weights, or otherwise issued ‘approximately.’ (e.g.: paint, ingredients, chemicals etc.)
• • Where a ‘spare’ quantity needs to be returned to stock after manufacturing is finished. (e.g.: scrapings, leftovers, recycled material.)

In SQLWorks every component on a Bill of Material (BOM) has a default allocation method – either ‘Standard’, ‘Backflush’ or ‘Return’ which defines how stock of this item will be ‘used up’ in the Stock Ledger. These work as follows:

• • ‘Standard’ – This is the default, and is used for all items that need to be counted out in advance of production. Components will be removed from stock when the user clicks ‘Take’ on the Works Order, before production begins.
• • ‘Backflush’ – Components will only be removed from stock after the Works Order is built, and the user is then asked to specify how much has been used.
• • ‘Return’ – Similar to backflushing, however components will only be removed from stock after the Works Order is built, and the user is then asked to specify a ‘spare’ quantity that gets returned to stock.

By changing a component stock item to ‘Backflush’ on a BOM, nothing will be removed from stock at the ‘Take’ stage, instead being deducted only after that BOM has been ‘built’ on a Works Order. The user can then specify how much has (or hasn’t) been used.

This is significantly more practical for certain items – although production managers may need to initially estimate the stock quantity of a Backflush item that they expect to use on its BOM (e.g.: how much paint an item typically needs.)

The user can edit a component’s default type by right clicking on it in a BOM, and choosing ‘Change Component Type.’ Components set to Backflush will be marked with a small ‘B’ symbol in the BOM.

When ‘Taken’ within a Works Order, only Standard items will listed as being removed from stock, and Backflush items will always show a taken quantity of zero (with the user then prompted after the ‘build’ stage for the correct quantity used for Backflush, or quantity excess for Return.)

For many manufacturers, drawing down stock ‘post-production’ in this way may be the only way to accurately update your usage of resources. Using backflushing is an efficient way of tracking manufacturing using more fluid components, and allows SQLWorks to keep your production precise.

SQLWorks Version 10 is officially live on both Microsoft Windows 11, with early tests suggesting a significant performance improvement.

Microsoft Windows 11 is the first major Windows release for six years, and introduces a raft of visual, technical and security updates to the world’s most widespread desktop operating system.

Our SQLWorks Software Development Team – which uses both Apple macOS and Microsoft Windows for development – works hard to ensure our software maintains the best possible lifespan and interoperability, without the need for companies to spend on paid version upgrades. This includes advance testing on preview build/upcoming operating systems via virtual machine, to ensure our customers won’t experience compatibility issues.

You can learn more about upgrading to Windows 11 here, including the require minimum specifications. Uptake across industry PCs is expected to be somewhat slower than for Windows 10, as many pre-2018 processors prior to the Spectre and Meltdown incidents won’t support the update – meaning that the adoption of Windows 11 will be driven predominantly by new devices.

SQLWorks is still fully operable on any 64-bit version of Windows 10, which itself remains fully supported by Microsoft until October 2025.

 

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Setting up pricing and discounting rules enables the end user to better manage customer accounts, and stock items.  Rules are restrictions or qualifiers that qualify the rule, and they are only applied if that condition is met.  You can create and set, specific rules for stock item costs and descriptions which are linked to individual customers.  As well as set parameters for when these price and discount rules will be automatically applied.

Managing pricing and discounting rules across multiple customer accounts and stock items can sometimes get quite complicated and tricky to keep on top of.  SQLWorks has made this process easier to set up, control and manage giving you greater flexibility and accuracy ensuring rules are adhered to across the whole of your customer portfolio.

The pricing and discount summary page gives managers and admin personnel the ability to view all rules that have been created, as well as the control to amend and save at a top level, which will automatically apply these rules across the platform.

The module can be found on the main nav bar under the Products Extras section.  The rules can be viewed on multiple tabs, and pricing rules can be imported and exported in bulk quickly and efficiently using an xls or csv file.  Discounting rules can be applied as line discount or an order discount, giving you the flexibility and control to apply rules at various stages of the ordering process.

Alternatively, rules can be viewed and managed from the Sales Ledger or Stock Ledger.  In both ledgers the Price & Discounts tab can be found in the top section of the window.  The rules listed apply specifically to the sales account or stock item selected and can be added, deleted and edited from this tab.  Once added the rules are linked to the corresponding ledger automatically and any order created that meets the criteria of one of these set rules, will adjust automatically..

Examples of the different types of rules that can be applied:

1. Qty or value price breaks to reduce cost for higher value orders
2. Limited time promotions
3. Discounts by brand or other custom fields
4. Specific prices or discounts by delivery site or currency
5. Order level discounts based on value
6. Customer specific part names & descriptions
7. Priority based rules for complex ordering systems
8. Rules targeting categories of SL account or product
9. Separate rules for trade or retail customers
10. Combinations of all of the above

To use customer specific part names & description to search for the item when creating a new customer order it is slightly different, using the customer lookup icon – as shown below.  Part names and descriptions automatically adjust on the item line once the criteria of a rule is met.

For more information, please see our full guide on Pricing and discounting features, or contact our team today.

Query Builder:

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Query builder is a powerful reporting tool that advanced users can use to interrogate the SQLWorks database, cross-reference data in new ways, and get insight from business analytics.

Working in steps across the screen, Query Builder guides the user across four main tabs including ‘Setup’, ‘Tables’, ‘Conditions’ and ‘Preview.’

Setup tab allows users to create new queries, and choose the base layer data for their query from their SQLWorks database. For convenience, users can save queries here, opt whether to share them with other users, and re-run their favourites to generate new results as system data is updated.

In the Tables tab, the user can drag in related tables to cross reference different data within the database, and build new comparative reports that don’t already exist by default by selecting one or more data columns from within those tables.

The Conditions tab is perhaps the most powerful – allowing the user to assemble or subdivide the existing data in ways to extract very specific report outputs. Three tools are available here – Filter By, Sort By, and Group By. Filter By options can be used flexibly to exclude irrelevant data an target subsets, while Sort By allows you to re-order everything based on a specific table column to highlight priority data first.

Group By allows users to aggregate data in powerful ways – for example totally values per company, automatically calculating averages into value fields, or totalling costs. Programming criteria are available to do this, including ‘Distinct’, ‘Count’, ‘Concatenate’, ‘Maximum’, ‘Minimum’, ‘Sum’ and ‘Average’ – with columns ordered or re-designated to structure the report as you wish.

In the Preview tab, users can preview the results of their query and export to a range of formats including Excel spreadsheet (.xlsx), Comma-separated value (.csv), text (.txt), PDF (.pdf), print formats, or even email the results direct to themselves.

We hope users will find Query Builder to be a potent weapon in their arsenal of reporting tools – giving you new ways to identify patterns, compare and contrast relative data, or summarise from a new perspective.

 

For more information, please see our full guide to using query builder, or contact our team today.

Asset Register

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If a business harnesses important physical assets, keeping track of these over time quickly becomes essential.

Whether it’s your own machinery, or a piece of equipment you maintain for a client, attributing costs to these accurately is an key part of your business financial planning – and helps you make smarter decisions about future investment.

SQLWorks supports this process with a dedicated asset register – allowing the user to save a range of information (including make, model, warranty and more) for both in-house and client assets to aid day-to-day business operations. Asset Register can be found in the Stock Ledger, and helps the user build a centralised and definitive list that can be controlled with permissions groups, like any other SQLWorks Ledger.

For in-house assets, SQLWorks users can also link these assets to Purchase Orders – ensuring that asset’s data contains a detailed maintenance history that includes financials.

Helpfully, this also works across multiple Purchase Ledger suppliers, so that maintenance costs (such as repairs or replacement parts) remain accurate even if an asset’s service contract changes hands. This helps a company stay flexible, since accounting and contract periods may be much shorter than machinery lifecycles.

Assets may also be optionally enabled as a special tab in a customer’s Sales Ledger account – ensuring a service engineer can easily access known information about a client’s asset as a part of routine account maintenance. This might include location, serial numbering for identification, or notes on past repair work.

SQLWorks ensures business managers can properly document and maintain a full asset register – itself an asset to a well-informed team.

 

For expertise and software assistance, please contact our SQLWorks Team today

Made Smarter Update:

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Lineal’s SQLWorks Software is officially registered as a specialist UK digital technologies provider for manufacturing.

Made Smarter is a UK-Government backed initiative launched in 2017, following a nationwide review of the manufacturing sector – and includes a number of private and public sector organisations helping to modernise industry and drive adoption of productivity-boosting technology in the sector.

Recognised fields include a wide range of next-generation technologies for manufacturing such as robotics & process control, data and systems integration, mobile and wearable devices, sensor innovations, machine learning, additive manufacturing and augmented reality technology.

“We’re delighted to see SQLWorks listed among some of this country’s most advanced and cutting-edge technology solutions for manufacturing” said Lineal’s Managing Director Mike Matthews. “The Made Smarter review highlights adoption of modern technology as a keystone for industry in this country, and we want SQLWorks to underpin real advancement and strength in the industry.”

Businesses can read the original findings of the Made Smarter Review here, and learn more about Made Smarter UK here.

 

For Business Software expertise and support, please contact our team today.