Tag Archive: Manufacturing

One of the key elements of Sage 200 2013 is the choice of deployment that it offers. Companies can now choose between an On-Premise and an Online (Cloud) deployment.

Cloud ERP solutions are becoming a serious option for companies. This is increasingly due to the savings they can make on infrastructure requirements such as the latest Hardware, Security and Backup systems. In the past, companies have been wary about how secure Cloud solutions are, as their key business data is involved. But Cloud solutions (generally) have much more sophisticated security and data recovery systems than what business can implement internally.

Sage 200 2013 Online has no upfront expenses for hardware just a single monthly subscription fee. You pay for what you use and there is more flexibility than before to add and remove users or modules.

With Line 100 becoming end of life in April 2014; Sage 200 online offers more companies an affordable upgrade option without the loss of key functionality, as now there is an upgrade option for Sage 200 without the added costs of new servers and other required components such as Microsoft SQL server.

For certain businesses it can still make sense to invest upfront, They may wish to keep data in-house and have the resources required to invest in technology/infrastructure as well as continue ongoing maintenance.

On-Premise has all the same functionality as Online, but the addition of modules which are not currently available to the online option. Therefore the requirements ofa company may dictate which option they can go for. For example if a Manufacturing solution is required, the On-Premise deployment would need to be implemented.














Project Accounting











This document from Sage gives further details about the differences between Sage 200 2013 On-premise and Online.

An issue has been found within the Estimating module for Sage 200 2011 SP3.

The issue occurs when a user amends an estimate by adding a new stage or amending an existing stage on the estimate. If this is done, some stages will then have duplications of Stock items that were already added.

A hotfix has now been released.

A known issue has been fixed for Sage 200 2011 SP3.

Some Manufacturing sites found that when recording a POP Invoice for One-Off Works Orders it causes an exception:

1. Create a One-Off Works Order with components that have unconfirmed costs.

2. Raise a POP order for the components and receive in full.

2. Allocate, issue and complete the Works Order.

3. Fully record the POP invoice.

System generates a “Divide By Zero” exception.

The known issue is 4627.  Sage has released a hotfix that must be applied to  Sage 200 2011 sp3 only.

Be aware of a known issue in Sage 200 2011 SP3 that affects Manufacturing WIP postings. It has be found that incorrect cost is posted to the WIP nominal account, when responding to “Cost of Sale” posting from POP if multiple POP Invoices are recorded:

1. Create a Works Order with components that have unconfirmed costs.

2. Raise a POP order for the components and receive in full on multiple GRNs.

3. Allocate, issue and complete the Works Order.

4. Part record the POP invoice.

5. Fully record rest of POP invoice.

Invalid nominal postings are made for the cost of sales on the 2nd GRN.

This known issue is logged as issue 4591, however a hotfix has been released and should be installed for Manufacturing sites running Sage 200 2011 SP3.

If a user tries to expand MRP tags, where the parent tag is for multiple recommendations, the system can become unresponsive and run out of memory.

From testing Sage have found that this is more apparent when there are large quantities of tagged demand, which have generated thousands of recommendations. Sage 200 does not attempt to cache any data fetched for a particular tag and so if it meets the same tag in the tree hierarchy elsewhere it will attempt to explode it again.

This is known issue 4618. A hotfix has now been released and should only be applied to Manufacturing sites that have Sage 200 2011 SP3.

Service Pack 3 has now been released for Sage 200 2011. The main focus is on CRM fixes but there are also a few Manufacturing and Core module fixes/updates.

This service pack rolls up service packs 1 and 2 as well as any hot fixes that proceeded them. SP3 also includes documentation updates for Deployment and Integration Guide, System Requirements, CRM Implementation Guide and Upgrading Sage 200 CRM.

A full list of included fixes is available in the attached document: –

Issues fixed in Service Pack 3 for Sage 200 2011

Fixes/Updates of note include the following:

Core Modules

  • There is a now a setting to stop the ability to enter NL Payments/Receipts with different dates for each side of the posting i.e. current functionality allows the bank side to have one date and the transaction side to have another date.
  • Validation option for second reference on Invoices and Credit Notes.
  • The ‘Posting order line’ message does not clear when the POP order entry form is closed without saving. This has now been fixed.
  • The nominal accounts assigned to project items are not retained when a project is amended. This has now been fixed.


  • New workspaces have been created for the Manufacturing modules.
  • Graphical Planner 11.2 is included.


  • Where BOM allocations include multiple BOMs, the ‘Undo Allocation’ option incorrectly removes the whole allocation. This has now been fixed


  • Cannot print a prospect quote entered via form launching for a prospect company in CRM.
  • The ‘Company Type’ must be re-selected when changes are made to the company summary screen if the ‘Company Type’ has been made a mandatory field.
  •  A ‘Progress’ tab has been added to the integration: ‘Administration > Integration > Integration Name | Progress’. The progress tab displays the number of records remaining to be synchronised.

Sage have found and fixed an issue with Sage 200 Manufacturing, when substituting a traceable component within Works Order Processing (WOP).

The issue is described by Sage as follows:

If you use the “Substitute Traceable Component” feature to amend an already complete Works Order, either to add extra components or to remove components, the issue quantity on the Works Order Allocation/Issue does not get updated to reflect the correct quantity that has been issued. This has the effect of making the Works Order total cost not being correct based on the actual costs incurred.

A hotfix has been released for Sage 200 2011 SP2 Manufacturing. This fixes an issue where the Create Sales Order Tick Box on the Create WO Dialogue doesn’t work.


For Manufacturing sites, please be aware of a hotfix release for Sage 200 2011 SP2.

This hotfix brings Works Orders into line with Bill of Materials, for converting Stock unit quantities.

Works Orders previously converted all quantities to stock units and then multiplied by the quantity required. Bill of Materials (Trial Kitting) multiplies the component quantities by the assembly quantity required and then converts to the stock units.

This hotfix makes Works Orders use the same method as BOM.

I have finally managed to look through the 2011 new features for BOM/Manufacturing.

The 2010 release saw some functionality lost that allowed users to update Operation details on mass. This was due to the changes made to the new BOM module. With all due respect this was an error, and in some cases became an upgrade stopper.

The GOOD NEWS is that 2011 (as promised) sees the return of this functionality.


Labour, Machine and Tools registers each have an update function that will allow you to update Resources to be based on their group settings. E.g. Labour items can be updated to reflect the settings attributed to the Labour Resource Group that they are assigned to.

The properties that can be updated in each register are:

  • Cost Heading
  • Cost Nominal Account
  • Allow Cost Rate Override
  • Overhead Nominal Account
  • Efficiency %
  • Overhead Recovery %
  • Time Units


Operations have two separate options. 

Operation Update Details allows users to update the BOM Operation details (i.e. operations settings assigned to BOM records) to reflect the default settings assigned within the Operations register.

I.e. if you amend the default settings of an Operation(s) in the register, this routine will update these changes to the BOM’s with these operations.

You are able to update the following details:

  • Resources
  • Sub-contractor details
  • Overlap (Manufacturing only)
  • Run Time
  • Delay (Manufacturing only)
  • Shrinkage (Manufacturing only)
  • Notes

A useful option is whether you update BOM Operations that were manually amended to be specific to an individual BOM.

There is a lot of flexibility with this function as you are able to decide the BOM records that are updated.

E.g. If the Operation selected to update is assigned to 10 BOMs, the system will show the 10 BOM’s it is on, and you are then able to remove the BOMs that you do not want updated.

The system has an important validation process that lists Exclusions and Warnings, for those BOM’s that can’t be updated. May be they are on Hold, do not have an active version etc.

Update Operation Rates allows you to update Cost rates on Resources/Operations that are already on a BOM Operation.

Firstly you select a Source Type from:

                Resource Record (Labour/Machine/Tools)

                Resource Group (Labour/Machine/Tool)

                Operation Records

Then select the specific source:

                I.e. if you selected the type Resource record, now select Labour/Machine or Tools Register.

Then select the Target record:



                BOM Operations

I.e. what is it that you want to update?

If BOM Operations are being updated then a validation process is done. You then have the option to select specific BOM records that you wish to update. Where BOM records are being updated, you are given the option to re-cost the BOMs.

Bill of Materials

Add Component

This is utility allows you to add a component to Multiple BOMs. Simple and effective!

BOM Costing Analysis

There is now a Graphical analysis to allow better visualisation of the costing effects.

New settings allow you to determine the default behaviour for the cost analysis screen.

  • Select what data the charts display
    • Date range used
    • How to show sub-assembly costs
    • Whether multiple versions are shown
  • Select what values to show
    • Unit Cost including overheads
    • Suggest selling price
    • Profit
  • How the Chart is displayed, such as colours and labelled axis.

When the costing screen is viewed you are able to select two graphical views of the data. Analysis shows you a costing analysis with Unit Cost, Profit and Suggested Selling Price.

Actual Comparison shows the difference between planned costs and Actual costs. Planned costs are costing sessions done from within the BOM record. Actual costs are from the BOM Build/Confirm Build process.

For manufacturing sites, Works order Planned and Actual comparisons are also shown.

The first question end users will ask is – Can the Graph be printed? The answer is really, No; although there is a button to copy it to the clipboard!

BOM Reverse Build

The long-awaited BOM reverse build is introduced in 2011. This allows users to reverse the build of a BOM, previously completed within BOM. Effectively the function is a dismantle function to correct user error.

The feature is only for BOM builds, and not Manufacturing builds.

A new list view shows a list of BOM build records, and the whole reversal process can be managed from this list.

There a number of restrictions and outcomes to be aware of with this function, in particular:

  • You cannot partially reverse
  • The system checks that the stock of the finished item CREATED BY THE BUILD is still available.
  • An AVERAGE cost re-calculation is performed on finished items reversed from stock.
  • Nominal postings use the same Transaction Date & URN as the original build entry.
  • FIFO rules are NOT applied when items are returned to stock.
  • If the original build was created from a BOM allocation, then a New BOM allocation is created by the reversal.

BOM Workspace

A new BOM workspace in 2011 gives users an improved view of BOM records.


For me these new features are all improvements to what was already available. It seems that it has all been about making long jobs simpler for users.

Each feature will be a benefit to the user in the function that they are designed to perform.

The BOM reversal function may not go far enough for some people; who would have hoped to have been able to reverse BOMs for salvage type operations. However in the main I think that it will work for most and will be a worthwhile reason to upgrade.