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AutoCount - Multi-Level Stock Assembly Module

Introduction to AutoCount Multi-Level Stock Assembly

AutoCount's Multi-Level Stock Assembly Module is an advanced extension of the standard Stock Assembly feature. To clarify, designed for manufacturers and assemblers, this module simplifies the production of complex finished goods made from multiple semi-finished components. Imagine building a bicycle. It's made of several semi-finished components like the wheels, handlebar and frame. As a result, with Multi-Level Stock Assembly, AutoCount allows you to combine all of these in one go. Thus, ensuring efficient stock deduction and accurate costing. Therefore, this article will guide you through every step—from setup to application—and help you unlock the full power of this module.

Benefits of Multi-level stock assembly module

Streamlined Production Processes

Firstly, with one-click assembly, you no longer needs to record every intermediate step. The system automates deductions across multiple layers of Bill of Materials (BOM). Thus, speeding up operations.

Costing Accuracy

Secondly, the module auto-calculates finished goods costs by aggregating costs from each sub-item and child item. Thus, ensuring that the pricing reflects current market values and production costs.

Real-Time Inventory Sync

Thirdly, each component’s stock level is updated immediately. Thus, reducing discrepancies and enhancing real-time stock control.

Setting Up the assembly module in autoCount

How to Enable the Module

To begin, ensure that the Assembly Module has been purchased and activated:

  • Firstly, navigate to ‘Tools’ > ‘Program Control’ > ‘Module Setting’
  • Secondly, tick the checkbox for ‘Multi-Level Assembly’
  • Thirdly, click ‘OK’ to confirm
multi-level stock assembly module

Accessing Module Settings

Once activated, the module settings can be accessed under the stock management section, where users can configure BOM and material deduction rules.

Understanding Semi-Finished Goods and BOM Structure

Defining Semi-Finished Goods

Semi-Finished Goods are partially completed products used as components in final assemblies. For example, a bicycle wheel is a semi-finished good.

Creating Accurate BOM Hierarchies

Setting a structured BOM (Bill of Materials) is essential:

  • Firstly, go to ‘Stock’ > ‘Stock Item Maintenance’
  • Secondly, seAftlect a semi-finished product and click ‘Edit’
  • After that, under the BOM section, list the required raw materials
multi-level stock assembly module

Ensure to update BOM costing using the option: Up-To-Date Cost from sub items up-to-date-cost.

Step-by-Step setup for multi-level assembly

Configuring Semi-Finished Goods

Example: Semi-Finished Goods 1 (e.g., bicycle frame)

  • Firstly, remove obsolete raw materials
  • Secondly, insert current materials with accurate quantities

Assigning Raw Materials

Use updated inventory codes and assign:

  • Raw Material 1: Quantity = 3
  • Raw Material 2: Quantity = 2
multi-level stock assembly module

Setting Update BOM Cost Rules

Always apply the rule to reflect real-time costing from child items.

Managing Finished Goods in Multi-Level BOM

Replacing Raw Materials with Semi-Finished Goods

In the BOM of Finished Goods:

  • Firstly, remove raw material used in semi-finished goods
  • Secondly, add the relevant semi-finished good as a replacement

Inquiring BOM Material Analysis

Use the following:

  • ‘Inquiry’ > Check ‘BOM Material Inquiry’
  • Enable ‘Multi-Level’ option for full material breakdown

Using the Multi-Level assembly functionality

Converting to Multi-Level View

When creating a new Stock Assembly:

  • Firstly, select ‘Finished Goods 1’
  • Secondly, use ‘Convert to Multi-Level’ to reveal component structure
multi-level stock assembly module

Impact on Raw Material Deduction

Without conversion, the system doesn’t deduct raw materials from sub-items. With it, deductions occur automatically. Thus, enhancing accuracy.

Stock Assembly Section Enhancements

Auto Update & Costing Calculations

The system:

  • Deducts stock from both sub-items and child items
  • Calculates cost automatically from all levels

Manual Adjustments and Tracking

Users can still manually adjust components before finalizing the assembly

Implementing BOM Option for Shild Items

How BOM Options Work?

BOM Options allow flexible substitution when material run low.

Setting Up Alternative for Raw Materials

Go to: 

  • ‘Stock’ > ‘BOM Optional’
  • Create a new rule:
    • E.g., If Raw Material 1 is short by 3, replace with 3 units of Raw Material 2
multi-level stock assembly module

Using BOM Option with finished and semi-finished goods

Configuration Examples

  • Finished Goods 1: Replace Packaging Material 1 with Packaging Material 2
  • Semi-Finished Goods 1: Replace Raw Material 1 with Raw Material 2
multi-level stock assembly module

Material Substitution Scenarios

Enable Apply BOM Optional with the Child Item checkbox for substitutions at all levels.

Analyzing Sub-Item composition with BOM Inquiry

Multi-Level Filter Options

AutoCount provides an in-depth BOM Material Inquiry tool that enables users to analyze the entire composition of a finished product, even when multiple layers of sub-assemblies are involved.

Steps: 

  • Firstly, go to ‘Inquiry’ > ‘Check BOM Material Inquiry’
  • Secondly, select the desired ‘Finished Goods’
  • Thirdly, check the ‘Multi-Level’ box
  • After that, click ‘Inquiry’ to view full sub-item breakdown

This feature is particularly useful when dealing with complex products composed of several semi-finished components and ensures visibility at every level.

Real-Time Breakdown of Assemblies

The system not only displays the primary BOM components but also drills down into each sub-item to display their raw materials, costs and availability in real time. This functionality simplifies production planning and inventory forecasting.

Reporting and Inventory monitoring features

  • Generating BOM Reports

    Users can generate detailed BOM reports for internal auditing, material planning and costing analysis. These reports include:

    • The data exported from the top option is well-formatted based on the layout you customized in the module.
    • This ensures the exported file is tidy and structured, especially for Excel files, as it uses the specified format you set in the module.

  • Tracking Assembly Status

    From within the Stock Assembly Module, users can:

    • View history of assembled items
    • Check stock deduction logs
    • Monitor pending assemblies and stock reservation status

    This transparency streamlines inventory control and boosts operational efficiency.

Common Use Cases for Manufacturers and assemblers

Real-World Scenarios

  • Bicycle Manufacturing: Frame, wheels and gears are semi-finished goods that get assembled into a complete unit.
  • Furniture Production: Tables with pre-assembled legs and tops combined into final pieces.
  • Electrics Assembly: Semi-finished circuits and boards integrated into final gadgets.

Industries Benefitting Most

  • Automotive
  • Consumer Electronics
  • Furniture and Home Decor
  • Packaging and Plastics
  • Industrial Equipment

These industries often require nested assembly workflows, which makes the Multi-Level Stock Assembly module a game-changer.

Integration with other autoCount modules

Stock, Sales and Manufacturing Modules Synergy

When integrated with other AutoCount modules, Multi-Level Stock Assembly becomes even more powerful:

  • Stock Module

    Real-time updates of raw materials and finished goods.

  • Sales Module

    Assembly triggered from confirmed sales orders.

  • Manufacturing Module

    Comprehensive production planning and scheduling.

By synchronizing these modules, AutoCount ensures consistency across departments and eliminates redundancy.

Tips for effective use of the module

Best Practices:

  • Always keep BOMs up to date to ensure accurate costing.

  • Use the Convert to Multi-Level feature during assembly creation.

  • Regularly audit BOM Optional setups to maintain optimal substitutions.

  • Test BOM settings in a sandbox before deploying in live environments.

Avoiding Common Pitfalls:

  • Forgetting to enable Child Item when applying BOM Optional.

  • Skipping BOM cost updates, leading to inaccurate finished goods pricing.

  • Not maintaining raw material stock levels, causing production delays.

Troubleshooting multi-level assembly issues

Common Errors and Fixes

Issue 1:

Issue: Raw Materials not deducted from semi-finished goods.

Solution: Ensure 'Convert to Multi-Level' is applied during assembly.

Issue 2:

Issue: Costing not reflecting latest updates.

Solution: Check the BOM cost setting for 'Up-To-Date Cost from sub items'.

Issue 3:

Issue: BOM Optional not triggering replacement.

Solution: Verify that the replacement rule is active and applies to the correct item level.

Support Resources:

Technical Support Hotline

AutoCount User Manual

Online Knowledge Base

Trusted AutoCount Dealer

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Conclusion

To conclude, the AutoCount Multi-Level Stock Assembly Module is a robust solution for businesses that require precision and efficiency in manufacturing. It automates raw material deduction, maintains real-time stock accuracy and ensures cost integrity through multi-layer BOM integration. So, whether you are assembling bicycles, electronics or furnitures, this module offers the tools that manage complex workflows with ease.

As a result, by following the guidelines and best practices in this guide, businesses can achieve higher productivity, reduced errors and improved profitability using AutoCount’s ERP platform.

FAQs

It streamlines the production process by allowing a single-step assembly of finished goods from multiple levels of components, saving time and improving accuracy.

Yes, by using the BOM Optional feature, you can configure alternative materials that auto-replace when the primary item is insufficient.

Absolutely! It scales according to the business size and works well for both small workshops and large manufacturing units.

Enable ‘Update BOM Cost’ to pull the latest cost from sub-items and regularly review your BOM configurations.

The system will not deduct the raw materials used in the semi-finished goods, leading to inaccurate stock and costing records.

Yes, the BOM Material Inquiry and Stock Assembly Reports provide full visibility across all layers of assembly.

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