Overhead and labour cost changed to define standard costs.
[fa-stable.git] / manufacturing / includes / db / work_orders_db.inc
index 15ea30f7cd3dbb70e05b622bbdfad06769b03c24..11c9204fdf37f5c9ca45cd0bba2eeff82b6d66f6 100644 (file)
     MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  
     See the License here <http://www.gnu.org/licenses/gpl-3.0.html>.
 ***********************************************************************/
-//--------------------------------------------------------------------------------------
-
-function add_material_cost($stock_id, $qty, $date_, $advanced=false, $woid=0)
-{
-       $m_cost = 0;
-    $result = get_bom($stock_id);
-       while ($bom_item = db_fetch($result))
-       {
-               $standard_cost = get_standard_cost($bom_item['component']);
-               $m_cost += ($bom_item['quantity'] * $standard_cost);
-       }
-       $bom_cost = $m_cost;
-       // new 2015.10.15       
-       // additilnal costs.
-       $i_cost = 0;
-       if ($woid != 0 && work_order_has_issues($woid))
-       {
-               $res = get_additional_issues($woid);
-               while ($issue = db_fetch($res))
-               {
-                       $standard_cost = get_standard_cost($issue['stock_id']);
-                       $i_cost += ($issue['qty_issued'] * $standard_cost) / $qty;
-               }
-       }
-       $sql = "SELECT material_cost, labour_cost, overhead_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
-               .db_escape($stock_id);
-       $result = db_query($sql);
-       $myrow = db_fetch($result);
-       $material_cost =  $myrow['material_cost'] - $i_cost; // $i_cost was already added to material cost
-       $m_cost += $i_cost;
-       /* no, why will we do that?? Joe Hunt 2015.10.17
-       if ($advanced)
-       {
-               //reduce overhead_cost and labour_cost from price as those will remain as is
-               $m_cost = $m_cost - $myrow['labour_cost'] - $myrow['overhead_cost'];
-       }
-       */
-       $qoh = get_qoh_on_date($stock_id);
-       $cost_adjust = false;
-       if ($qoh < 0)
-       {
-               if ($qoh + $qty >= 0)
-                       $cost_adjust = true;
-               $qoh = 0;
-       }               
-       if ($qoh + $qty != 0)
-       {
-               if ($qoh == 0) // 27.10.2014 apmuthu and dz.
-                       $material_cost = $m_cost;
-               else    
-                       $material_cost = ($qoh * $material_cost + $qty * $m_cost) /     ($qoh + $qty);
-       }
-       if ($advanced && $cost_adjust) // new 2010-02-10
-               adjust_deliveries($stock_id, $bom_cost, $date_);        
-       
-               $sql = "UPDATE ".TB_PREF."stock_master SET material_cost=".db_escape($material_cost)."
-                   WHERE stock_id=".db_escape($stock_id);
-       db_query($sql,"The cost details for the inventory item could not be updated");
-}
-
-function add_overhead_cost($stock_id, $qty, $date_, $costs, $adj_only=false)
-{
-       if ($qty != 0)
-               $costs /= $qty;
-       $sql = "SELECT overhead_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
-               .db_escape($stock_id);
-       $result = db_query($sql);
-       $myrow = db_fetch($result);
-       $overhead_cost =  $myrow['overhead_cost'];
-       $qoh = get_qoh_on_date($stock_id);
-       if ($qoh < 0)
-               $qoh = 0;
-       if ($adj_only)
-       {
-               if ($qoh>0)
-               {
-                       if ($qoh + $qty != 0)   
-                               $overhead_cost = ($qoh * $overhead_cost + $qty * $costs) /      ($qoh + $qty);
-                       elseif ($qty == 0)
-                               $overhead_cost = ($qoh * $overhead_cost + $costs) / $qoh;
-               }                       
-               else // Journal Entry if QOH is 0/negative 
-               {
-                       global $Refs;
-
-                       $id = get_next_trans_no(ST_JOURNAL);
-                       $ref = $Refs->get_next(ST_JOURNAL);
-                       
-                       $stock_gl_code = get_stock_gl_code($stock_id);
-                       $memo = "WO Overhead cost settlement JV for zero/negative respository of ".$stock_id;
-                       //Reverse the inventory effect if $qoh <=0
-                       add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
-                               $stock_gl_code["inventory_account"],
-                               $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo, 
-                               -$costs);
-                       //GL Posting to inventory adjustment account
-                       add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
-                               $stock_gl_code["assembly_account"], // changed 2015.10.14 from adjustment to assembly account. Petros.
-                               $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo,
-                               $costs);
-                               
-                       add_audit_trail(ST_JOURNAL, $id, $date_);
-                       add_comments(ST_JOURNAL, $id, $date_, $memo);
-                       $Refs->save(ST_JOURNAL, $id, $ref);
-                       if ($qty != 0) // 27.10.2014 dz
-                               $overhead_cost = ($qoh * $overhead_cost + $costs) / $qty;
-               }
-       }
-       else
-       {               
-               if ($qoh + $qty != 0)   
-                       $overhead_cost = ($qoh * $overhead_cost + $qty * $costs) /      ($qoh + $qty);
-       }
-       $sql = "UPDATE ".TB_PREF."stock_master SET overhead_cost=".db_escape($overhead_cost)."
-               WHERE stock_id=".db_escape($stock_id);
-       db_query($sql,"The cost details for the inventory item could not be updated");
-}
-
-function add_labour_cost($stock_id, $qty, $date_, $costs, $adj_only=false)
-{
-       if ($qty != 0)
-               $costs /= $qty;
-       $sql = "SELECT labour_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
-               .db_escape($stock_id);
-       $result = db_query($sql);
-       $myrow = db_fetch($result);
-       $labour_cost =  $myrow['labour_cost'];
-       $qoh = get_qoh_on_date($stock_id);
-       if ($qoh < 0)
-               $qoh = 0;
-       if ($adj_only)
-       {
-               if ($qoh>0)
-               {
-                       if ($qoh + $qty != 0)   
-                               $labour_cost = ($qoh * $labour_cost + $qty * $costs) /  ($qoh + $qty);
-                       elseif ($qty == 0)
-                               $labour_cost = ($qoh * $labour_cost + $costs) / $qoh;
-               }               
-               else // Journal Entry if QOH is 0/negative 
-               {
-                       global $Refs;
-
-                       $id = get_next_trans_no(ST_JOURNAL);
-                       $ref = $Refs->get_next(ST_JOURNAL);
-                       
-                       $stock_gl_code = get_stock_gl_code($stock_id);
-                       $memo = "WO labour cost settlement JV for zero/negative respository of ".$stock_id;
-                       //Reverse the inventory effect if $qoh <=0
-                       add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
-                               $stock_gl_code["inventory_account"],
-                               $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo, 
-                               -$costs);
-                       //GL Posting to inventory adjustment account
-                       add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
-                               $stock_gl_code["assembly_account"], // changed 2015.10.14 from adjustment to assembly account. Petros.
-                               $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo,
-                               $costs);
-                               
-                       add_audit_trail(ST_JOURNAL, $id, $date_);
-                       add_comments(ST_JOURNAL, $id, $date_, $memo);
-                       $Refs->save(ST_JOURNAL, $id, $ref);     
-                       if ($qty != 0) // 27.10.2014 dz
-                               $labour_cost = ($qoh * $labour_cost + $costs) / $qty;
-               }
-       }
-       else
-       {               
-               if ($qoh + $qty != 0)   
-                       $labour_cost = ($qoh * $labour_cost + $qty * $costs) /  ($qoh + $qty);
-       }       
-       $sql = "UPDATE ".TB_PREF."stock_master SET labour_cost=labour_cost+".db_escape($labour_cost)."
-               WHERE stock_id=".db_escape($stock_id);
-       db_query($sql,"The cost details for the inventory item could not be updated");
-}
-
-function add_issue_cost($stock_id, $qty, $date_, $costs, $adj_only=false)
-{
-       if ($qty != 0)
-               $costs /= $qty;
-       $sql = "SELECT material_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
-               .db_escape($stock_id);
-       $result = db_query($sql);
-       $myrow = db_fetch($result);
-       $material_cost =  $myrow['material_cost'];
-       $qoh = get_qoh_on_date($stock_id);
-       if ($qoh < 0)
-               $qoh = 0;
-       if ($adj_only)
-       {
-               if ($qoh>0)
-                       $material_cost = ($qoh * $material_cost + $costs) / $qoh;
-               else // Journal Entry if QOH is 0/negative
-               {
-                       global $Refs;
-
-                       $id = get_next_trans_no(ST_JOURNAL);
-                       $ref = $Refs->get_next(ST_JOURNAL);
-                       
-                       $stock_gl_code = get_stock_gl_code($stock_id);
-                       $memo = "WO Issue settlement JV for zero/negative respository of ".$stock_id;
-                       //Reverse the inventory effect if $qoh <=0
-                       add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
-                               $stock_gl_code["inventory_account"],
-                               $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo, 
-                               -$costs);
-                       //GL Posting to inventory adjustment account
-                       add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
-                               $stock_gl_code["assembly_account"], // changed 2015.10.14 from adjustment to assembly account. Petros.
-                               $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo,
-                               $costs);
-                               
-                       add_audit_trail(ST_JOURNAL, $id, $date_);
-                       add_comments(ST_JOURNAL, $id, $date_, $memo);
-                       $Refs->save(ST_JOURNAL, $id, $ref);
-                       if ($qty != 0) // 27.10.2014 dz
-                               $material_cost = $costs / $qty; 
-               }
-       }
-       else
-       {
-               if ($qoh + $qty != 0)   
-                       $material_cost = ($qoh * $material_cost + $qty * $costs) /      ($qoh + $qty);
-       }       
-       $sql = "UPDATE ".TB_PREF."stock_master SET material_cost="
-               .db_escape($material_cost)
-               ." WHERE stock_id=".db_escape($stock_id);
-       db_query($sql,"The cost details for the inventory item could not be updated");
-}
-
+/*
+       Common entry procedure for all work order types
+*/
 function add_work_order($wo_ref, $loc_code, $units_reqd, $stock_id,
        $type, $date_, $required_by, $memo_, $costs, $cr_acc, $labour, $cr_lab_acc)
 {
        global $Refs;
 
-       if (!($type == WO_ADVANCED))
-               return add_work_order_quick($wo_ref, $loc_code, $units_reqd, $stock_id, $type, $date_, $memo_, $costs, $cr_acc, $labour, $cr_lab_acc);
-
        begin_transaction();
        $args = func_get_args();
        $args = (object)array_combine(array('wo_ref', 'loc_code', 'units_reqd', 'stock_id',
                'type', 'date_', 'required_by', 'memo_', 'costs', 'cr_acc', 'labour', 'cr_lab_acc'), $args);
+
        $args->woid = 0;
        hook_db_prewrite($args, ST_WORKORDER);
 
-       add_material_cost($stock_id, $units_reqd, $date_);
+       if ($type != WO_ADVANCED)
+               $required_by = $date_;
 
        $date = date2sql($date_);
        $required = date2sql($required_by);
-
        $sql = "INSERT INTO ".TB_PREF."workorders (wo_ref, loc_code, units_reqd, stock_id,
                type, date_, required_by)
        VALUES (".db_escape($wo_ref).", ".db_escape($loc_code).", "
@@ -275,6 +46,25 @@ function add_work_order($wo_ref, $loc_code, $units_reqd, $stock_id,
 
        $args->woid = $woid;
        hook_db_postwrite($args, ST_WORKORDER);
+
+       if ($type != WO_ADVANCED)
+       {
+               $stockitem = get_item($stock_id);
+               release_work_order($woid, $date_, '');
+               if ($costs != 0)
+                       add_wo_costs_journal($woid, $costs, WO_OVERHEAD, $cr_acc, $stockitem["assembly_account"],
+                               $date_, $stockitem["dimension_id"], $stockitem["dimension2_id"]);
+               if ($labour != 0)
+                       add_wo_costs_journal($woid, $labour, WO_LABOUR, $cr_lab_acc, $stockitem["assembly_account"],
+                               $date_, $stockitem["dimension_id"], $stockitem["dimension2_id"]);
+
+               if ($type == WO_UNASSEMBLY)
+                       $units_reqd = -$units_reqd;
+
+               $ref = $Refs->get_next(ST_MANURECEIVE, null, $date_);
+               work_order_produce($woid, $ref, $units_reqd, $date_, '', true);
+       }
+
        commit_transaction();
 
        return $woid;
@@ -283,7 +73,7 @@ function add_work_order($wo_ref, $loc_code, $units_reqd, $stock_id,
 //--------------------------------------------------------------------------------------
 
 function update_work_order($woid, $loc_code, $units_reqd, $stock_id,
-                                       $date_, $required_by, $memo_, $old_stock_id, $old_qty)
+                                       $date_, $required_by, $memo_)
 {
        begin_transaction();
        $args = func_get_args();
@@ -291,9 +81,6 @@ function update_work_order($woid, $loc_code, $units_reqd, $stock_id,
                'date_', 'required_by', 'memo_'), $args);
        hook_db_prewrite($args, ST_WORKORDER);
 
-       add_material_cost($old_stock_id, -$old_qty, $date_);
-       add_material_cost($stock_id, $units_reqd, $date_);
-
        $date = date2sql($date_);
        $required = date2sql($required_by);
 
@@ -317,8 +104,6 @@ function delete_work_order($woid, $stock_id, $qty, $date)
        begin_transaction();
        hook_db_prevoid(ST_WORKORDER, $woid);
 
-       add_material_cost($stock_id, -$qty, $date);
-
        // delete the work order requirements
        delete_wo_requirements($woid);
 
@@ -337,8 +122,10 @@ function delete_work_order($woid, $stock_id, $qty, $date)
 function get_work_order($woid, $allow_null=false)
 {
     $sql = "SELECT wo.*,st.description As StockItemName,l.location_name,
-               l.delivery_address,l.email, l.contact
-               FROM ".TB_PREF."workorders wo, ".TB_PREF."stock_master st, ".TB_PREF."locations l
+               l.delivery_address,l.email, l.contact, st.inventory_account, st.assembly_account
+               FROM ".TB_PREF."workorders wo, "
+                       .TB_PREF."stock_master st, "
+                       .TB_PREF."locations l
                WHERE st.stock_id=wo.stock_id
                AND     l.loc_code=wo.loc_code
                AND wo.id=".db_escape($woid)."
@@ -347,7 +134,10 @@ function get_work_order($woid, $allow_null=false)
        $result = db_query($sql, "The work order issues could not be retrieved");
 
        if (!$allow_null && db_num_rows($result) == 0)
+       {
                display_db_error("Could not find work order $woid", $sql);
+               return false;
+       }
 
        return db_fetch($result);
 }
@@ -399,7 +189,7 @@ function release_work_order($woid, $releaseDate, $memo_)
                released=1 WHERE id = ".db_escape($woid);
        db_query($sql, "could not release work order");
 
-       // create Work Order Requirements based on the bom
+       // create wo_requirements records according to current BOM
        create_wo_requirements($woid, $stock_id);
 
        add_comments(ST_WORKORDER, $woid, $releaseDate, $memo_);
@@ -427,14 +217,24 @@ function work_order_is_closed($woid)
 }
 
 //--------------------------------------------------------------------------------------
-
-function work_order_update_finished_quantity($woid, $quantity, $force_close=0)
+/*
+       Update finished items quantity in work order, and close order either if all the order is produced,
+       or on user demand. Returns calculated unit cost on close, or null otherwise.
+*/
+function work_order_update_finished_quantity($woid, $quantity, $date, $force_close=0)
 {
-       $sql = "UPDATE ".TB_PREF."workorders SET units_issued = units_issued + ".db_escape($quantity).",
-               closed = ((units_issued >= units_reqd) OR ".db_escape($force_close).")
-               WHERE id = ".db_escape($woid);
+
+       $sql = "UPDATE ".TB_PREF."workorders SET units_issued = units_issued + ".db_escape($quantity)."
+               WHERE id = ".db_escape($woid). " AND !closed";
 
        db_query($sql, "The work order issued quantity couldn't be updated");
+
+       $sql = "UPDATE ".TB_PREF."workorders SET closed = ((units_issued >= units_reqd) OR ".db_escape($force_close).")
+               WHERE id = ".db_escape($woid);
+
+       db_query($sql, "The work order couldn't be closed");
+
+       return db_num_affected_rows();  // returns 1 if WO has been closed
 }
 
 //--------------------------------------------------------------------------------------
@@ -447,6 +247,13 @@ function void_work_order($woid)
        $work_order = get_work_order($woid);
        if (!($work_order["type"] == WO_ADVANCED))
        {
+               // restore average product costs 
+               $date = sql2date($work_order['date_']);
+               $qty = $work_order['units_reqd'];
+
+               // FIXME: update_material_cost
+
+               // close workorder
                $sql = "UPDATE ".TB_PREF."workorders SET closed=1,units_reqd=0,units_issued=0 WHERE id = "
                        .db_escape($woid);
                db_query($sql, "The work order couldn't be voided");
@@ -454,8 +261,8 @@ function void_work_order($woid)
                // void all related stock moves
                void_stock_move(ST_WORKORDER, $woid);
 
-               // void any related bank/gl trans
-               void_bank_trans(ST_WORKORDER, $woid, true);
+               // void any related costing records
+               void_wo_costing($woid);
 
                // clear the requirements units received
                void_wo_requirements($woid);
@@ -464,46 +271,41 @@ function void_work_order($woid)
        {
                // void everything inside the work order : issues, productions, payments
                $date = sql2date($work_order['date_']);
-               
+
+               // FIXME: update_material_cost
+
                $result = get_work_order_productions($woid); // check the produced quantity
+               $qty = 0;
                while ($row = db_fetch($result))
                {
-                       void_work_order_produce($row['id']);
-                       
-                       //Post voided entry if not prevoided explicitly
-                       $void_entry = get_voided_entry(ST_MANURECEIVE, $row['id']);
-                       if ($void_entry)
-                               continue;
-                       $memo_ = _("Voiding Work Order Trans # ").$woid;
-                       add_audit_trail(ST_MANURECEIVE, $row['id'], today(), _("Voided.")."\n".$memo_);
-                       add_voided_entry(ST_MANURECEIVE, $row['id'], today(), $memo_);
-               }
+                       $qty += $row['quantity'];
+                       // clear the production record
+                       $sql = "UPDATE ".TB_PREF."wo_manufacture SET quantity=0 WHERE id=".$row['id'];
+                       db_query($sql, "Cannot void a wo production");
 
-               $result = get_work_order_issues($woid);
+                       void_stock_move(ST_MANURECEIVE, $row['id']); // and void the stock moves; 
+               }
+               $result = get_additional_issues($woid); // check the issued quantities
                $cost = 0;
+               $issue_no = 0;
                while ($row = db_fetch($result))
                {
-                       void_work_order_issue($row['issue_no']);
-                       
-                       //Post voided entry if not prevoided explicitly
-                       $void_entry = get_voided_entry(ST_MANUISSUE, $row['issue_no']);
-                       if ($void_entry)
-                               continue;
-                       $memo_ = _("Voiding Work Order Trans # ").$woid;
-                       add_audit_trail(ST_MANUISSUE, $row['issue_no'], today(), _("Voided.")."\n".$memo_);
-                       add_voided_entry(ST_MANUISSUE, $row['issue_no'], today(), $memo_);                              
-               }
+                       $unit_cost = get_unit_cost($row['stock_id']);
+                       $icost = $unit_cost * $row['qty_issued'];
+                       $cost += $icost;
+                       if ($issue_no == 0)
+                               $issue_no = $row['issue_no'];
+                       // void the actual issue items and their quantities
+                       $sql = "UPDATE ".TB_PREF."wo_issue_items SET qty_issued = 0 WHERE issue_id="
+                               .db_escape($row['id']);
+                       db_query($sql,"A work order issue item could not be voided");
+               }       
+               if ($issue_no != 0)
+                       void_stock_move(ST_MANUISSUE, $issue_no); // and void the stock moves 
 
-               //Adust avg labour cost
-               $cost = get_gl_wo_cost($woid, WO_LABOUR); 
-               if ($cost != 0)
-                       add_labour_cost($work_order['stock_id'], 1, $date, -$cost, true);
-                       
-               //Adust avg overhead cost
-               $cost = get_gl_wo_cost($woid, WO_OVERHEAD); 
                if ($cost != 0)
-                       add_overhead_cost($work_order['stock_id'], 1, $date, -$cost, true);
-               
+                       add_issue_cost($work_order['stock_id'], -$qty, $date, $cost);
+
                $sql = "UPDATE ".TB_PREF."workorders SET closed=1,units_reqd=0,units_issued=0 WHERE id = "
                        .db_escape($woid);
                db_query($sql, "The work order couldn't be voided");
@@ -512,11 +314,12 @@ function void_work_order($woid)
                void_stock_move(ST_WORKORDER, $woid);
 
                // void any related bank/gl trans
-               void_bank_trans(ST_WORKORDER, $woid, true);
+               void_wo_costing($woid);
 
                // clear the requirements units received
                void_wo_requirements($woid);
        }
+
        commit_transaction();
 }
 
@@ -576,6 +379,7 @@ function get_sql_for_work_orders($outstanding_only, $stock_id, $location = ALL_T
 
                $sql .= " AND workorder.required_by < '$Today' ";
        }
+       $sql .= " ORDER BY workorder.id DESC";
        return $sql;
 }
 
@@ -604,6 +408,6 @@ function get_gl_wo_cost($woid, $cost_type)
        $result = get_gl_wo_cost_trans($woid, $cost_type);
        while ($row = db_fetch($result))
                $cost += -$row['amount'];
-       return $cost;   
+       return $cost;
 }