Lab Praktikum

BAB 09
Manufacturing

BOM, Manufacturing Orders, dan Production Cost Analysis di Odoo 19

Minggu 10 120 Menit Individu / Pasangan Opsional*

*Wajib untuk UMKM manufaktur; opsional untuk retail/trading/jasa
Sistem Informasi Enterprise — ERP Odoo 19.0

Timeline 120 min

Konfigurasi Modul Manufacturing
Aktifkan Work Orders, By-Products · Buat 2 Work Centers · Verify Routes

15 min

Membuat Bill of Materials
3 BOM: Batik Cap + Batik Tulis + Kemeja Batik · Components + Routing + By-Products

40 min

Manufacturing Order — Eksekusi Penuh
MTS Manual (20 unit) + MTO dari SO · Check Availability · Produce · Scrap · Validate

40 min

Subcontracting Simulation
BOM tipe Subcontracting · PO ke vendor jahit · Transfer komponen otomatis

15 min ⚡

Production Cost Analysis
Standard vs Actual · Variance breakdown · Scrap rate analysis

10 min

🎯 Output: 10 screenshots wajib + 2 bonus → ZIP file Lab9_[NIM]_[Nama].zip · Step 4 opsional (⚡)

🤔 Apakah UMKM Saya Butuh Manufacturing?

Self-Assessment (5 pertanyaan)

UMKM mengubah bahan baku → produk jadi?
Ada resep/formula/BOM untuk produk?
Proses produksi > 1 tahap?
Ada stok WIP (barang setengah jadi)?
Biaya produksi penting untuk harga jual?

Skor 4–5: Lab penuh · 2–3: Minimal Step 1–3 · 0–1: Skip, dalami modul lain

Prasyarat Teknis

Odoo 19 aktif + login Manufacturing access
Produk BBS dari Lab Bab 4–6 tersedia
Chart of Accounts dari Lab Bab 8
Stok RM: Kain Mori 50m, Malam 2kg, Pewarna 10 set

⚠️ Data belum lengkap? Import: Settings → Technical → Import Data → file demo

Tujuan Lab

🔧 T1 — Mengaktifkan & mengkonfigurasi modul Manufacturing + Work Centers di Odoo 19

📋 T2 — Membuat BOM lengkap: Components + Routing + By-Products untuk 3 produk BBS

🏭 T3 — Mengeksekusi Manufacturing Order: Create → Check → Produce → Scrap → Validate

📊 T4 — Menganalisis production cost variance (Standard vs Actual) & scrap rate

Step 1 · 15 menit

Konfigurasi
Manufacturing

🎯 Aktifkan Work Orders + By-Products, buat 2 Work Centers, verifikasi product routes

Settings, Work Centers & Routes

1.1 Aktifkan Settings

Manufacturing → Configuration → Settings
Centang: Work Orders ✅
Centang: By-Products ✅
Centang: Subcontracting ✅ (opsional)
Klik Save

1.2 Buat 2 Work Centers

Manufacturing → Configuration → Work Centers → New

Field	Batik Station	QC & Packaging
Working Hours	08–17 Mon-Sat	08–17 Mon-Sat
Time Efficiency	85%	90%
Capacity	2	3
Costs per hour	Rp 15.000	Rp 12.000

1.3 Verifikasi Route Produk

Inventory → Products → pilih produk BBS → tab Inventory → pastikan Routes: ☑ Manufacture

✅ Checkpoint Step 1

Manufacturing Settings: Work Orders + By-Products aktif
2 Work Centers terbuat (Batik Station + QC & Packaging)
Produk BBS memiliki route "Manufacture"

📸 SCREENSHOT 9.1: Manufacturing Settings (Work Orders aktif)
📸 SCREENSHOT 9.2: 2 Work Centers yang sudah dibuat

Work Orders tab tidak muncul di MO? → Pastikan fitur Work Orders sudah diaktifkan di Settings dan sudah klik Save.

Step 2 · 40 menit

Bill of
Materials

🎯 Buat 3 BOM: Batik Cap Premium + Batik Tulis Premium + Kemeja Batik

BOM Batik Cap Premium

Manufacturing → Products → Bills of Materials → New · Product: Batik Cap Premium · Qty: 1 pcs · Type: Manufacture This Product

Tab Components

Komponen	Qty	UoM
Kain Mori Primissima	2,0	meter
Malam Batik	0,05	kg
Pewarna Naptol (set)	1	set
Cap Batik (motif)	1	set

Tab Operations

Operasi	Work Center	Durasi
Pola & Cap	Batik Station	45 min
Pewarnaan & Finishing	Batik Station	60 min
QC & Packaging	QC & Packaging	30 min

Tab By-Products

Sisa Kain Mori: 0,3 kg (Cost Share 2%) · Malam Bekas: 0,1 kg (Cost Share 1%) → Save → catat BOM Cost

BOM Batik Tulis + Kemeja

BOM #2: Batik Tulis Premium

Komponen	Qty
Kain Mori Primissima	2,5 m
Malam Batik	0,08 kg
Pewarna Naptol (set)	1 set

Routing: Pola & Canting (120 min) → Pewarnaan & Lorod (90 min) → QC (45 min)

⏱️ Total: 255 min vs 135 min (Cap) — ini yang bikin Batik Tulis mahal!

BOM #3: Kemeja Batik Short Sleeve

Komponen	Qty
Kain Batik Cap (jadi)	1,5 m
Benang Jahit	100 m
Kancing Kemeja	7 pcs
Interlining	0,3 m

Atau buat BOM untuk produk UMKM mitra Anda sendiri.

2.4 Verifikasi: Structure & Cost

Buka BOM → klik Structure & Cost → verifikasi semua komponen + harga → 📸 SCREENSHOT 9.3 & 9.4

✅ Checkpoint Step 2

3 BOM tersimpan: Batik Cap, Batik Tulis, Kemeja Batik
Setiap BOM: Components + Operations (Routing) terisi
BOM Batik Cap: By-Products (Sisa Kain + Malam Bekas) dikonfigurasi
Structure & Cost menampilkan BOM Cost untuk setiap produk

BOM Cost = Rp 0? → Buka setiap produk komponen → set Purchase Price. Tanpa harga beli, BOM Cost tidak bisa dihitung.

Step 3 · 40 menit

Manufacturing
Orders

🎯 Skenario A: MTS Manual 20 unit · Skenario B: MTO dari SO

3.1 Buat MO + Check Availability

Skenario A: MTS — Manual MO (20 unit Batik Cap)

Manufacturing → Manufacturing Orders → New
Product: Batik Cap Premium · Quantity: 20 · Scheduled Date: +3 hari
BOM otomatis terisi → klik Confirm
Klik Check Availability → verifikasi semua komponen hijau/reserved

Komponen	Dibutuhkan	Status
Kain Mori (2m × 20)	40 meter	Cek stok → ✅ / ⚠️
Malam Batik (0,05 × 20)	1 kg	Cek stok → ✅ / ⚠️
Pewarna Naptol	20 set	Cek stok → ✅ / ⚠️
Cap Batik	1 set	Cek stok → ✅ / ⚠️

Shortage? → Klik komponen yang kurang → Replenish → Odoo buat draft PO → Confirm → Receive → Check Availability lagi.

3.4 Eksekusi Produksi + Catat Scrap

Produksi dengan Waste 10%

Klik Produce → form produksi terbuka
Ubah konsumsi aktual: Kain Mori dari 40m → 44m (10% waste)
Komponen lain: biarkan sesuai BOM
Qty produced: 20 pcs

3.5 Catat Scrap

1 lembar kain (2m) rusak terkena noda:

Klik Scrap di toolbar MO
Product: Kain Mori Primissima · Quantity: 2 meter
Klik Done

3.6 Validasi MO

Pastikan semua Work Orders Finished → klik Validate → jika popup backorder → No Backorder

📸 SCREENSHOT 9.5: MO Confirmed + Check Availability · 📸 9.6: Form produksi (waste 44m) · 📸 9.7: MO Validated (Done)

3.7 Verifikasi + Skenario B (MTO)

Verifikasi Hasil MO

Inventory: Batik Cap Premium +20 pcs
Journal Entry: RM out → WIP → FG in (klik "Journal Entry" di MO)
Cost: Catat Standard vs Actual di form MO

📸 SCREENSHOT 9.8: Inventory +20 · 📸 9.9: Journal Entry

Skenario B: Auto MO dari SO

Sales → Orders → New
Customer: Demo · Product: Batik Tulis Premium (route MTO) · Qty: 5
Confirm SO → buka Manufacturing → MO
MO baru muncul otomatis linked ke SO!

📸 SCREENSHOT 9.10: SO → auto MO terlink

MO tidak muncul saat SO confirmed? → Buka produk → tab Inventory → pastikan route Make to Order tercentang, bukan hanya Manufacture.

✅ Checkpoint Step 3

MO Batik Cap Premium: 20 pcs produced, status Done
Actual consumption Kain Mori: 44m (vs standard 40m) — waste 10%
Scrap: 2m Kain Mori tercatat
Inventory Batik Cap Premium bertambah 20 pcs
Journal Entry terbuat otomatis (RM → WIP → FG)
MTO: SO trigger auto MO terconfirm

Step 4 · 15 menit · Opsional ⚡

Subcontracting
Simulation

🎯 Buat BOM tipe Subcontracting + PO ke vendor jahit → komponen otomatis dikirim

BOM Subcontracting + PO

4.1 Buat Subcontracting BOM

Manufacturing → Bills of Materials → New

Product: Kemeja Batik Jadi (Subcontract)
BOM Type: Subcontracting
Subcontractors: [pilih vendor/tailor]
Components: Kain Batik Cap 1.5m + Benang 100m + Kancing 7 pcs

4.2 Buat PO ke Subcontractor

Purchase → Orders → New
Vendor: [subcontractor] · Product: Kemeja Batik Jadi · Qty: 10 · Price: Rp 35.000
Confirm PO → transfer komponen otomatis terbuat
Verifikasi: komponen BBS terkirim ke vendor lokasi

📸 BONUS B1: Subcontracting BOM + PO dengan transfer komponen otomatis (+10 poin)

Step 5 · 10 menit

Production
Cost Analysis

🎯 Standard vs Actual → Variance breakdown → Scrap rate analysis

Analisis Variance & Scrap

5.1 Cost Analysis Report

Manufacturing → Reporting → Cost Analysis → filter MO yang baru dibuat

Metrik	Isi dari Report
Standard Cost (total)	Rp ___
Actual Cost (total)	Rp ___
Variance (Rp)	Rp ___
Variance (%)	___%

5.3 Production Analysis

Manufacturing → Reporting → Production Analysis
Group by: Product → total MO & qty
Group by: Work Center → beban kerja

5.4 Scrap Rate

Inventory → Reporting → Moves Analysis → filter: Scrap

Scrap Rate = Scrap Qty ÷ Total Input × 100%
2m ÷ 44m = 4.5%

📸 SCREENSHOT 9.10: Cost Analysis Report (standard vs actual) + tabel variance manual

✅ Checkpoint Step 5

Cost Analysis Report: Standard vs Actual teridentifikasi
Variance positif (unfavorable) — karena waste 10% Kain Mori
Production Analysis: volume & durasi per produk terbaca
Scrap rate ~4.5% (benchmark garment 5–8% — BBS cukup baik!)

💡 Analisis: Variance >5% harus diselidiki. Penyebab utama di lab ini: waste kain 10%. Rekomendasi: review teknik cap untuk kurangi sisa kain, atau negosiasi harga kain bulk untuk offset waste cost.

Adaptasi per Tipe UMKM

Aspek	Garment/Batik	Furniture	F&B Produksi	Manufaktur Ringan
BOM Focus	Multi-level + Routing	Single-level + By-product	UoM kompleks (kg/L)	BOM sederhana
MO Style	MTS + MTO + Scrap	MTO-heavy	Batch + Lot tracking	MTS + Variance
Work Centers	4 stasiun (cap/tulis/jahit/QC)	3 (potong/amplas/finish)	2 (prep/masak)	2–3 sesuai proses
Key Challenge	Waste kain + konsistensi	Estimasi kayu + pricing	Shelf life + volume	Cost accuracy

🪑 Furniture: By-product utama (serbuk gergaji → briket). Profit Meja Ukir hanya 7% tanpa labor costing — harus koreksi harga!

🍜 F&B: Batch production 300 porsi/hari. Lot tracking wajib untuk traceability. HPP per menu kategori beda jauh.

📦 Deliverables

Kumpulkan: Lab9_[NIM]_[Nama].zip

📸 9.1 — Manufacturing Settings (Work Orders aktif)

📸 9.2 — 2 Work Centers dikonfigurasi

📸 9.3 — BOM Batik Cap Premium (Components + By-Products)

📸 9.4 — Structure & Cost

📸 9.5 — MO Confirmed + Check Availability

📸 9.6 — Form produksi (actual consumption 44m) · 📸 9.7 — MO Validated (Done)

📸 9.8 — Inventory +20 · 📸 9.9 — Journal Entry · 📸 9.10 — SO → auto MO (MTO)

Bonus: B1 — Subcontracting BOM + PO (+10 poin) · B2 — Analisis variance >5%: penyebab & rekomendasi (+10 poin)

Rubrik Penilaian

Kriteria	Poin	Baik (100%)	Kurang (<70%)
Step 1: Config + Work Centers	10	Settings aktif, 2 WC terbuat	WC tidak lengkap
Step 2: 3 BOM + Structure & Cost	15	Components + Routing + By-Products	BOM tanpa routing
Step 3a: MO MTS (20 unit)	20	Check → Produce → Scrap → Validate	MO belum validated
Step 3b: MO MTO dari SO	5	Auto MO terlink ke SO	MO manual (bukan auto)
Step 3: Inventory + JE verify	20	+20 FG, JE RM→WIP→FG	Stok/JE tidak sesuai
Step 5: Cost Analysis + Scrap	10	Variance + scrap rate dihitung	Report tidak difilter

Total: 80 poin wajib + 20 poin bonus = 100 poin.

🔧 Troubleshooting Quick Ref

BOM Cost = Rp 0? → Buka setiap produk komponen → set Purchase Price. Tanpa harga beli, Odoo tidak bisa hitung BOM Cost.

Check Availability semua merah? → Stok RM = 0. Buat PO → Receive → coba Check Availability lagi.

Scrap button tidak muncul? → MO masih Draft. Confirm MO terlebih dahulu — Scrap hanya tersedia pada MO yang sudah dimulai.

Jurnal tidak terbuat saat Validate? → Pastikan Accounting → Settings → Automatic Accounting aktif.

MO dari SO tidak muncul? → Produk harus punya route Make to Order + Manufacture keduanya tercentang.

Preview Minggu Depan

Bab 10: Human Resource Management

👥 Employee Master Data & Departments

📅 Attendance, Leave Management & Payroll

📊 HR Reports & Labor Cost Integration dengan Manufacturing

Selamat Praktikum! 🎉

Sistem Informasi Enterprise — ERP Odoo 19.0
dengan Real UMKM Partner Program

BAB 09Manufacturing