06 — Integrations & Consolidated Data Model

How the Manufacturing module connects to the existing ERP, plus the full relational model in one place. Inherits all rules from 00.

6.1 Integration Map

The Manufacturing module is NOT an island. It integrates with modules that already exist in the host ERP (do not rebuild them).

                    ┌─────────────┐
       Sales Order →│             │→ Procurement (Planned POs from MRP)
                    │ MANUFACTURING│
        Inventory  ↔│   MODULE     │↔ General Ledger (all postings)
   (RM, WIP, FG)    │             │
                    └─────────────┘
                       ↕ HR (labor rates / piece-rate payroll)

Integration points (by direction)

Key integration rules

• Consignment (toll): customer-owned material lives in a separate inventory bucket (ownership=Customer), never valued as own asset, never triggers purchase.
• GL postings are real-time, woven into execution events — not a nightly batch.
• Reservations in Inventory are created at order Release, consumed at Material Issue.

6.2 Consolidated Relational Data Model

All entities across the module, with keys and relationships. (Types are indicative; implement per host ERP conventions.)

MASTER DATA

Item                      (host ERP, referenced)
  item_id PK, name, uom, procurement_type, material_ownership,
  costing_method, lead_time_days, safety_stock, ...

BOM_Header
  bom_id PK, parent_item_id FK→Item, bom_type, version, base_quantity,
  uom, status, effective_from, effective_to, created_by, approved_by

BOM_Line
  bom_id FK→BOM_Header, line_no, component_id FK→Item, quantity, uom,
  scrap_percentage, issue_type, issue_level, operation_seq, substitute_items
  (BOM_Header 1—* BOM_Line)

Routing_Header
  routing_id PK, item_id FK→Item, routing_type, version,
  lot_size_from, lot_size_to, status, effective_from, effective_to, total_lead_time

Routing_Operation
  routing_id FK→Routing_Header, operation_no, description,
  work_center_id FK→Work_Center, tool_id FK→Tool,
  setup_time, run_time_per_unit, cavity_count, cycle_time,
  queue_time, move_time, inspection_required, critical_operation, required_skill_code
  (Routing_Header 1—* Routing_Operation)

Work_Center
  wc_id PK, description, category, plant_location, cost_center_id FK→Cost_Center,
  capacity_unit, daily_capacity, capacity_multiplier, efficiency_percent,
  utilization_percent, calendar_id, setup_cost_rate, labor_cost_rate,
  machine_cost_rate, overhead_rate, labor_calc, bottleneck_flag

Tool   (Resource, resource_type=Tool)
  tool_id PK, description, product_id FK→Item, cavity_count, setup_time,
  status, life_cycles, cycles_used, purchase_cost

PLANNING

MPS_Header
  id PK, plan_name, plant_id, time_bucket, start_date, end_date,
  frozen_fence, slushy_fence, status

MPS_Line
  mps_id FK→MPS_Header, product_id FK→Item, period_date, forecast_qty,
  confirmed_orders_qty, planned_production, projected_balance,
  safety_stock_target, available_to_promise

Item_MRP_Settings
  item_id FK→Item, mrp_type, procurement_type, material_ownership,
  lot_sizing_rule, lot_size, min_lot, max_lot, safety_stock,
  lead_time_days, reorder_point

MRP_Planned_Order   (transient — regenerated each run)
  item_id FK→Item, order_type, quantity, required_date, release_date,
  source_demand_id, mrp_run_id

CRP_Load            (output)
  resource_id, resource_type, period, required_load,
  available_capacity, utilization_pct, status

EXECUTION

Production_Order_Header
  order_no PK, order_type, product_id FK→Item, quantity, production_type,
  material_ownership, start_date, finish_date, status,
  bom_snapshot_id, routing_snapshot_id, tool_id FK→Tool, wip_account

Order_Component
  order_no FK→PO_Header, component_id FK→Item, required_quantity,
  issued_quantity, reserved_quantity, operation_seq

Order_Operation
  order_no FK→PO_Header, operation_no, work_center_id FK→Work_Center,
  tool_id FK→Tool, planned_setup_time, planned_run_time,
  actual_setup_time, actual_run_time, status, actual_start_time,
  actual_end_time, confirmed_by, confirmed_quantity, scrap_quantity
  (status ∈ Waiting/Ready/InProgress/Completed — used by SFC)

Material_Issue_Header
  issue_no PK, issue_date, issue_type, issue_level, order_no FK→PO_Header,
  operation_no, issuer_id, warehouse_from, status

Material_Issue_Line
  issue_no FK→MI_Header, material_code FK→Item, quantity, batch_no,
  cost_price, total_cost, bin_location, ownership

Confirmation_Header
  confirmation_no PK, order_no FK→PO_Header, operation_no,
  confirmation_type, operator_id, work_center_id, shift, timestamp

Confirmation_Yield
  confirmation_no FK→Conf_Header, grade_code, quantity, unit_sale_price

Confirmation_Detail
  confirmation_no FK→Conf_Header, scrap_quantity, rework_quantity,
  setup_time_actual, run_time_actual, labor_hours, machine_hours, reason_code

Goods_Receipt_Header
  gr_no PK, gr_date, order_no FK→PO_Header, receipt_type,
  warehouse_to, receiver_id, status

Goods_Receipt_Line
  gr_no FK→GR_Header, item_id FK→Item, received_quantity, grade_code,
  batch_no, bin_location, cost_per_unit, quality_status

COSTING

Standard_Cost
  item_id FK→Item, std_material_cost, std_labor_cost, std_overhead_cost,
  std_total_cost, last_updated, update_frequency

Cost_Center
  cc_id PK, type, parent_cc FK→Cost_Center, manager_id,
  budget_amount, actual_amount, status

Variance_Record
  order_no FK→PO_Header, variance_type, amount, percentage,
  classification, owner, investigation_flag

CROSS-CUTTING

Pegging   (Many-to-Many demand↔supply)
  production_order_id FK→PO_Header, sales_order_id FK→SalesOrder,
  allocated_quantity

Delivery_Schedule   (order splitting)
  schedule_id PK, parent_order_id FK→SalesOrder, quantity,
  scheduled_date, status, linked_production_order FK→PO_Header

6.3 Relationship Summary (key cardinalities)

Item 1—* BOM_Header 1—* BOM_Line *—1 Item (component)   [recursive multi-level]
Item 1—* Routing_Header 1—* Routing_Operation *—1 Work_Center
Routing_Operation *—1 Tool
Work_Center *—1 Cost_Center
Sales_Order *—* Production_Order  (via Pegging)
Sales_Order 1—* Delivery_Schedule
Production_Order 1—* Order_Component / Order_Operation
Production_Order 1—* Material_Issue 1—* Material_Issue_Line
Production_Order 1—* Confirmation 1—* Confirmation_Yield (grades)
Production_Order 1—* Goods_Receipt 1—* Goods_Receipt_Line (per grade)
Production_Order 1—* Variance_Record

6.4 Build Order (recommended for the AI builder)

1. Master Data entities + CRUD (BOM recursive, Routing, WC, Tool)
2. Item_MRP_Settings + Standard_Cost
3. MPS (forecast consumption, time fences, CTP)
4. MRP (recursive explosion, lot sizing, toll branch)
5. CRP (resource intersection, overload detection)
6. Production Order (snapshot, state machine, order network)
7. Material Issue (3 types, 3 levels, consignment)
8. Confirmation (grade distribution, piece-rate, postings)
9. Goods Receipt (multi-grade, variance gate, toll branch)
10. Costing (methods, elements, cost centers, 7 variances)
11. SFC (operation-status real-time, terminal UI, auto-advance, dashboard)
12. Integrations (Sales, Procurement, Inventory, GL, HR)

Each step depends on the prior. Honour the genericity mandate (file 00 §0.2) throughout.

6.5 Future Phases (identified, not specified)