How to Define Work Instructions and Material Usage in NetSuite Advanced Manufacturing

Key Takeaways

• NetSuite Advanced Manufacturing is sold as a quote-based add-on to your NetSuite subscription; monthly cost varies by package, scope, and contract terms
• The "Issued Step" column only populates when work orders are first created, not when edited later
• Work center name mapping between Advanced Manufacturing and NetSuite is the most common implementation failure point
• Mobile data capture significantly reduces time spent on manual clipboard-to-system entry
• Basic implementations can take several months, while complex deployments with advanced features often last 6-12 months or more

Understanding NetSuite's Manufacturing Capabilities for Work Instructions

NetSuite Advanced Manufacturing extends standard manufacturing routing capabilities through the Advanced Manufacturing Work Bench. This Manufacturing Execution System (MES) transforms basic NetSuite manufacturing into an interactive production control environment where detailed work instructions live alongside real-time material tracking.

The platform provides several interconnected components:

• Advanced Manufacturing Work Bench – Central command center for defining work instructions, material associations, and planned start/end times per operation
• Work Instructions & Traveler SuiteApp – Free add-on creating detailed process notes, step-by-step instructions, and printable barcode-enabled travelers
• Manufacturing Mobile – Wireless tablet/barcode scanning for real-time material consumption and production reporting
• Routing Configuration – Define operations with setup time, run rate, work centers, and material issuance points

For manufacturers in regulated industries, these capabilities support compliance requirements including FDA 21 CFR Part 11 for electronic records, ISO quality management standards, and cGMP requirements for pharmaceutical and food manufacturers.

Setting Up Effective Work Orders for Production Guidance

Before creating work orders with embedded instructions, you must configure the foundational elements correctly. The setup sequence matters—skipping steps creates downstream failures.

Enable Core Features

Look for options to enable these features under Company Settings:

• Assembly Items
• Advanced Bill of Materials (test in sandbox first—this cannot be easily disabled)
• Manufacturing Work in Process (WIP)
• Manufacturing Routing and Work Center

Then install these SuiteApps through the bundle installation interface:

• Advanced Manufacturing SuiteApp
• Work Instructions and Traveler SuiteApp (free)
• SCM Mobile Bundle (prerequisite for Manufacturing Mobile)
• Manufacturing Mobile SuiteApp

Configure Work Centers

Work center configuration is where most implementations fail. You must create matching work centers in both NetSuite and Advanced Manufacturing with identical names and statuses.

NetSuite Work Centers configuration:

• Define work center name (exact spelling critical)
• Set daily capacity in hours
• Configure available resources
• Establish shop calendar with operating hours

Advanced Manufacturing Work Centers setup:

• Enter AM Work Center name EXACTLY as it appears in NetSuite
• Match status (both Active or both Inactive)
• Complete Assets, Shop Calendar, and RCP Parameters subtabs

Any mismatch between these two systems can prevent scheduling from working correctly.. Establish a naming convention before setup and document all mappings.

For organizations wanting to understand how to create workflows that complement these manufacturing setups, workflow automation can trigger approvals and notifications when work orders reach specific stages.

Defining Bills of Materials for Accurate Material Usage

Accurate BOMs form the foundation for material tracking. Advanced BOM configuration determines which components auto-issue at specific operations and how the system tracks consumption.

Create BOMs with Material Associations

When creating new Bills of Materials:

• Select assembly item
• Add component items with quantities
• Check "Use Component Yield" if accounting for waste/scrap (required on both assembly BOM record AND Bill of Materials page)
• Create BOM Revisions for version control
• Remove inactive items from BOM Revision records BEFORE creating work orders

For each component, configure:

• Issued Step – Which operation consumes this material
• Auto-Issue – Whether material automatically reduces inventory when operation completes

A critical limitation exists: these fields only populate when work orders are first created, not when edited later. If your BOM changes after work order creation, you must close the existing work order and create a new one.

For quantity-based pricing updates on materials, see our guide on NetSuite CSV imports for item price levels.

Implementing WIP and Routing for Enhanced Production Control

WIP and Routings provide the operational backbone for work instruction delivery. Each routing operation becomes a container for detailed instructions that operators see on printed travelers or mobile devices.

Create Manufacturing Routings

When creating new routing templates:

• Select item (assembly)
• Enter routing template name
• Add operations in sequence with:
  • Manufacturing Work Center
  • Setup Time (minutes)
  • Run Rate (per unit)
  • Cost Template
  • Connection Type (Finish-to-Start for sequential operations)
• Check "Default" if this routing should apply automatically

Define Work Instructions on Routing Records

The Work Instructions tab on routing records contains your process documentation:

• Enter process notes in text fields
• Add step-by-step instructions for each operation
• Include URLs for reference documents
• Upload images (these print on traveler PDFs)

The Work Instructions and Traveler SuiteApp generates barcode-enabled PDF travelers from these routing records. Operators scan barcodes to report production, and the system tracks which instructions they followed.

For manufacturers needing labor costing and scheduling capabilities, the WIP & Routings module provides infinite capacity scheduling with Gantt charts, while Advanced Manufacturing adds finite capacity scheduling that respects resource constraints.

Integrating Work Instructions with Inventory Automation

Real-time material tracking requires connecting work instructions to NetSuite's inventory automation capabilities. The integration ensures materials auto-issue at correct operations while maintaining accurate inventory counts.

Configure Mobile Data Collection

Manufacturing Mobile deployment transforms material tracking from manual clipboards to real-time barcode scanning:

• Deploy wireless tablets/smartphones to shop floor
• Configure Data Scanner role with appropriate permissions
• Set bin preferences for material issuance
• Train operators on mobile workflows

Mobile workflows include:

• Set Assignment (Location, Work Center, Date, Shift)
• Select Work Order
• Report Production (scan barcode, enter quantity)
• Report Consumption (scan component barcode, enter quantity consumed)
• Report Downtime (select category/reason)
• Report Loss/Scrap (enter quantity, reason)
• Submit (posts to GL and inventory)

One documented limitation: the Advanced Manufacturing SuiteApp does not support automatic issuing of lot or serial-controlled items. Operators must manually scan and enter lot numbers via the mobile app.

Leveraging Custom Workflows for Manufacturing Needs

Custom workflows extend work instruction capabilities beyond standard configurations. NetSuite's workflow engine can trigger approvals, notifications, and automated actions based on manufacturing events.

Common manufacturing workflow applications include:

• Quality Hold Notifications – Trigger alerts when variance thresholds exceeded
• BOM Change Approvals – Route revision requests through engineering review
• Work Order Status Updates – Notify planners when operations complete
• Material Shortage Alerts – Flag when components fall below safety stock

For step-by-step guidance on building these automations, our NetSuite workflow guide covers the fundamentals.

Ensuring Accuracy with Material Pricing

Material costs flow through BOMs to work orders and ultimately to finished goods valuation. Accurate pricing ensures variance reports reflect actual cost performance rather than data entry errors.

Price Level Management

Configure item price levels to reflect:

• Standard costs for variance analysis
• Vendor-specific purchase prices
• Quantity break pricing for volume purchases
• Preferred vendor designations

For companies tracking additional costs beyond purchase price, landed cost implementation captures freight, duties, and handling charges on received materials.

Optimizing Labor Costing and Scheduling

Advanced Manufacturing enables labor tracking by operation, providing visibility into actual versus standard labor hours. This data feeds variance analysis and supports continuous improvement initiatives.

Labor Costing Configuration

• Define labor rates by work center or employee
• Configure cost templates for overhead allocation
• Establish standard hours per operation
• Enable real-time labor clock-in via mobile devices

The scheduling engine offers two modes:

• Forward Scheduling – Calculates end date from start date (supports concurrent operations)
• Backward Scheduling – Calculates start date from required completion date (sequential operations only)

A key constraint: only work orders in "Released" status will schedule correctly. Work orders in "Planned" status block finite scheduling calculations.

Troubleshooting Common Issues

Implementation challenges follow predictable patterns. Understanding these prevents costly delays and rework.

Work Centers Don't Schedule
Name mismatch between AM and NetSuite work centers causes this issue. Edit both records to match exact spelling and status.

Issued Step Column Blank
The work order was edited after creation. Create a new work order and finalize BOM before WO creation.

Traveler Print Timeout
Script yield limit too low. Set yield limit to 500 on deployment record.

Materials Not Auto-Issuing
"Use Component Yield" not checked, or dealing with lot/serial items. Check the box on BOM or manually issue lot/serial items.

Tablet Display Distorted
MaxCDN URLs blocked by firewall. Whitelist maxcdn domain.

Data Cleanup Requirements

Most implementations underestimate data preparation time. Budget significant time for BOM cleanup from legacy systems. Common issues include:

• Inactive items still referenced in BOMs
• Inconsistent naming conventions
• Missing cost data
• Outdated routing sequences

If you approach ~200,000 monthly transaction lines on the Standard service tier, you may need to evaluate a Premium/Enterprise tier upgrade as you near that threshold.

Why Anchor Group Helps Manufacturers Succeed with NetSuite

Configuring work instructions and material usage tracking requires more than following documentation—it demands hands-on experience with the specific failure points that derail implementations. As an Oracle NetSuite Partner, Anchor Group brings deep manufacturing industry expertise to every project.

Our team has configured work orders, assembly builds, BOMs, WIP, routing, labor costing, and scheduling for manufacturers across wholesale distribution, discrete manufacturing, and process industries. Client Tripp Perkins noted that consultant Mitch was "super helpful in getting us back on track with NetSuite customizations/implementation of WIP/Routings" and "didn't take long to pick up on our processes."

The Anchor Group approach focuses on:

• Proper Work Center Mapping – We establish naming conventions and test configurations before full deployment
• BOM Validation – Data cleanup and validation happen before work order creation
• Traveler Customization – Our team handles XML modifications for custom fields
• Post-Implementation Support – Questions arise after go-live; we stay in your corner to resolve them

For manufacturers evaluating their NetSuite manufacturing setup, our 30-Minute Fix consultation provides quick answers to configuration questions. For comprehensive implementation support, explore our full NetSuite services offering.

Frequently Asked Questions

How long does it take to implement work instructions in NetSuite Advanced Manufacturing?

Basic implementations can take several months, while complex deployments with advanced features often last 6-12 months or more. Timeline depends heavily on data cleanup requirements—manufacturers with clean BOMs and consistent naming conventions move faster. Budget significant time specifically for legacy data preparation.

Can work instructions be customized for travelers?

Yes, but customization requires XML expertise. The standard Work Instructions & Traveler SuiteApp works well out-of-box, but adding fields like bin locations or changing layouts requires Professional Services engagement. Budget varies for traveler template customizations depending on scope and who implements it. Alternatively, include detailed instructions in the standard text fields and reference separate documents via URLs.

Why aren't my materials auto-issuing when operations complete?

Three common causes exist. First, verify "Use Component Yield" is checked on both the assembly BOM record and Bill of Materials page. Second, confirm you created a NEW work order after finalizing BOM settings—the Issued Step and Auto-Issue columns only populate on initial work order creation. Third, check if materials use lot or serial tracking, as the Advanced Manufacturing SuiteApp does not support automatic issuing of lot/serial items.

What's the difference between WIP & Routings and Advanced Manufacturing?

WIP & Routings provides work centers, routings, labor costing, and infinite capacity scheduling with Gantt charts. Advanced Manufacturing adds finite capacity scheduling (respects resource constraints), the Manufacturing Work Bench for centralized control, mobile barcode scanning for shop floor data capture, batch/lot traceability, and real-time variance management. Choose WIP & Routings for job shops with 5-10 work centers; choose Advanced Manufacturing for regulated industries or high-volume operations.

How do I fix work center scheduling failures?

Work center scheduling fails when names don't match exactly between Advanced Manufacturing Work Centers and NetSuite Work Centers. Both must have identical spelling and status. Create a spreadsheet documenting the 1-to-1 mapping before setup. Also verify work orders are in "Released" status—work orders remaining in "Planned" status do not schedule regardless of work center configuration.