Fixed wrong calculaiton of standard cost during Advanced Manufacturing. Petros.
[fa-stable.git] / manufacturing / includes / db / work_orders_db.inc
1 <?php
2 /**********************************************************************
3     Copyright (C) FrontAccounting, LLC.
4         Released under the terms of the GNU General Public License, GPL, 
5         as published by the Free Software Foundation, either version 3 
6         of the License, or (at your option) any later version.
7     This program is distributed in the hope that it will be useful,
8     but WITHOUT ANY WARRANTY; without even the implied warranty of
9     MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  
10     See the License here <http://www.gnu.org/licenses/gpl-3.0.html>.
11 ***********************************************************************/
12 //--------------------------------------------------------------------------------------
13
14 function add_material_cost($stock_id, $qty, $date_, $advanced=false, $woid=0)
15 {
16         $m_cost = 0;
17     $result = get_bom($stock_id);
18         while ($bom_item = db_fetch($result))
19         {
20                 $standard_cost = get_standard_cost($bom_item['component']);
21                 $m_cost += ($bom_item['quantity'] * $standard_cost);
22         }
23         $bom_cost = $m_cost;
24         // new Joe Hunt 2015.10.15      
25         // additilnal costs.
26         if ($woid != 0 && work_order_has_issues($woid))
27         {
28                 $res = get_additional_issues($woid);
29                 while ($issue = db_fetch($res))
30                 {
31                         $standard_cost = get_standard_cost($issue['stock_id']);
32                         $m_cost += ($issue['qty_issued'] * $standard_cost);
33                 }
34         }
35         $sql = "SELECT material_cost, labour_cost, overhead_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
36                 .db_escape($stock_id);
37         $result = db_query($sql);
38         $myrow = db_fetch($result);
39         $material_cost =  $myrow['material_cost'];
40         /* no, why will we do that?? Joe Hunt 2015.10.17
41         if ($advanced)
42         {
43                 //reduce overhead_cost and labour_cost from price as those will remain as is
44                 $m_cost = $m_cost - $myrow['labour_cost'] - $myrow['overhead_cost'];
45         }
46         */
47         $qoh = get_qoh_on_date($stock_id);
48         $cost_adjust = false;
49         if ($qoh < 0)
50         {
51                 if ($qoh + $qty >= 0)
52                         $cost_adjust = true;
53                 $qoh = 0;
54         }               
55         if ($qoh + $qty != 0)
56         {
57                 if ($qoh == 0) // 27.10.2014 apmuthu and dz.
58                         $material_cost = $m_cost;
59                 else    
60                         $material_cost = ($qoh * $material_cost + $qty * $m_cost) /     ($qoh + $qty);
61         }
62         if ($advanced && $cost_adjust) // new 2010-02-10
63                 adjust_deliveries($stock_id, $bom_cost, $date_);        
64         
65         $sql = "UPDATE ".TB_PREF."stock_master SET material_cost=".db_escape($material_cost)."
66                     WHERE stock_id=".db_escape($stock_id);
67         db_query($sql,"The cost details for the inventory item could not be updated");
68 }
69
70 function add_overhead_cost($stock_id, $qty, $date_, $costs, $adj_only=false)
71 {
72         if ($qty != 0)
73                 $costs /= $qty;
74         $sql = "SELECT overhead_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
75                 .db_escape($stock_id);
76         $result = db_query($sql);
77         $myrow = db_fetch($result);
78         $overhead_cost =  $myrow['overhead_cost'];
79         $qoh = get_qoh_on_date($stock_id);
80         if ($qoh < 0)
81                 $qoh = 0;
82         if ($adj_only)
83         {
84                 if ($qty != 0)
85                         $costs = $qty * $costs;
86                 if ($qoh>0)
87                         $overhead_cost = ($qoh * $overhead_cost + $costs) / $qoh;
88                 else // Journal Entry if QOH is 0/negative 
89                 {
90                         global $Refs;
91
92                         $id = get_next_trans_no(ST_JOURNAL);
93                         $ref = $Refs->get_next(ST_JOURNAL);
94                         
95                         $stock_gl_code = get_stock_gl_code($stock_id);
96                         $memo = "WO Overhead cost settlement JV for zero/negative respository of ".$stock_id;
97                         //Reverse the inventory effect if $qoh <=0
98                         add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
99                                 $stock_gl_code["inventory_account"],
100                                 $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo, 
101                                 -$costs);
102                         //GL Posting to inventory adjustment account
103                         add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
104                                 $stock_gl_code["assembly_account"], // changed 2015.10.14 from adjustment to assembly account. Petros.
105                                 $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo,
106                                 $costs);
107                                 
108                         add_audit_trail(ST_JOURNAL, $id, $date_);
109                         add_comments(ST_JOURNAL, $id, $date_, $memo);
110                         $Refs->save(ST_JOURNAL, $id, $ref);
111                         if ($qty != 0) // 27.10.2014 dz
112                                 $overhead_cost = ($qoh * $overhead_cost + $costs) / $qty;
113                 }
114         }
115         else
116         {               
117                 if ($qoh + $qty != 0)   
118                         $overhead_cost = ($qoh * $overhead_cost + $qty * $costs) /      ($qoh + $qty);
119         }
120         $sql = "UPDATE ".TB_PREF."stock_master SET overhead_cost=overhead_cost+".db_escape($overhead_cost)."
121                 WHERE stock_id=".db_escape($stock_id);
122         db_query($sql,"The cost details for the inventory item could not be updated");
123 }
124
125 function add_labour_cost($stock_id, $qty, $date_, $costs, $adj_only=false)
126 {
127         if ($qty != 0)
128                 $costs /= $qty;
129         $sql = "SELECT labour_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
130                 .db_escape($stock_id);
131         $result = db_query($sql);
132         $myrow = db_fetch($result);
133         $labour_cost =  $myrow['labour_cost'];
134         $qoh = get_qoh_on_date($stock_id);
135         if ($qoh < 0)
136                 $qoh = 0;
137         if ($adj_only)
138         {
139                 if ($qty != 0)
140                         $costs = $qty * $costs;
141                 if ($qoh>0)
142                         $labour_cost = ($qoh * $labour_cost + $costs) / $qoh;   
143                 else // Journal Entry if QOH is 0/negative 
144                 {
145                         global $Refs;
146
147                         $id = get_next_trans_no(ST_JOURNAL);
148                         $ref = $Refs->get_next(ST_JOURNAL);
149                         
150                         $stock_gl_code = get_stock_gl_code($stock_id);
151                         $memo = "WO labour cost settlement JV for zero/negative respository of ".$stock_id;
152                         //Reverse the inventory effect if $qoh <=0
153                         add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
154                                 $stock_gl_code["inventory_account"],
155                                 $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo, 
156                                 -$costs);
157                         //GL Posting to inventory adjustment account
158                         add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
159                                 $stock_gl_code["assembly_account"], // changed 2015.10.14 from adjustment to assembly account. Petros.
160                                 $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo,
161                                 $costs);
162                                 
163                         add_audit_trail(ST_JOURNAL, $id, $date_);
164                         add_comments(ST_JOURNAL, $id, $date_, $memo);
165                         $Refs->save(ST_JOURNAL, $id, $ref);     
166                         if ($qty != 0) // 27.10.2014 dz
167                                 $labour_cost = ($qoh * $labour_cost + $costs) / $qty;
168                 }
169         }
170         else
171         {               
172                 if ($qoh + $qty != 0)   
173                         $labour_cost = ($qoh * $labour_cost + $qty * $costs) /  ($qoh + $qty);
174         }       
175         $sql = "UPDATE ".TB_PREF."stock_master SET labour_cost=labour_cost+".db_escape($labour_cost)."
176                 WHERE stock_id=".db_escape($stock_id);
177         db_query($sql,"The cost details for the inventory item could not be updated");
178 }
179
180 function add_issue_cost($stock_id, $qty, $date_, $costs, $adj_only=false)
181 {
182         if ($qty != 0)
183                 $costs /= $qty;
184         $sql = "SELECT material_cost FROM ".TB_PREF."stock_master WHERE stock_id = "
185                 .db_escape($stock_id);
186         $result = db_query($sql);
187         $myrow = db_fetch($result);
188         $material_cost =  $myrow['material_cost'];
189         $qoh = get_qoh_on_date($stock_id);
190         if ($qoh < 0)
191                 $qoh = 0;
192         if ($adj_only)
193         {
194                 if ($qty != 0)
195                         $costs = $qty * $costs;
196                 if ($qoh>0)
197                         $material_cost = $costs / $qoh;
198                 else // Journal Entry if QOH is 0/negative
199                 {
200                         global $Refs;
201
202                         $id = get_next_trans_no(ST_JOURNAL);
203                         $ref = $Refs->get_next(ST_JOURNAL);
204                         
205                         $stock_gl_code = get_stock_gl_code($stock_id);
206                         $memo = "WO Issue settlement JV for zero/negative respository of ".$stock_id;
207                         //Reverse the inventory effect if $qoh <=0
208                         add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
209                                 $stock_gl_code["inventory_account"],
210                                 $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo, 
211                                 -$costs);
212                         //GL Posting to inventory adjustment account
213                         add_gl_trans_std_cost(ST_JOURNAL, $id, $date_, 
214                                 $stock_gl_code["assembly_account"], // changed 2015.10.14 from adjustment to assembly account. Petros.
215                                 $stock_gl_code['dimension_id'], $stock_gl_code['dimension2_id'], $memo,
216                                 $costs);
217                                 
218                         add_audit_trail(ST_JOURNAL, $id, $date_);
219                         add_comments(ST_JOURNAL, $id, $date_, $memo);
220                         $Refs->save(ST_JOURNAL, $id, $ref);
221                         if ($qty != 0) // 27.10.2014 dz
222                                 $material_cost = $costs / $qty; 
223                 }
224         }
225         else
226         {
227                 if ($qoh + $qty != 0)   
228                         $material_cost = ($qty * $costs) /      ($qoh + $qty);
229         }       
230         $sql = "UPDATE ".TB_PREF."stock_master SET material_cost=material_cost+"
231                 .db_escape($material_cost)
232                 ." WHERE stock_id=".db_escape($stock_id);
233         db_query($sql,"The cost details for the inventory item could not be updated");
234 }
235
236 function add_work_order($wo_ref, $loc_code, $units_reqd, $stock_id,
237         $type, $date_, $required_by, $memo_, $costs, $cr_acc, $labour, $cr_lab_acc)
238 {
239         global $Refs;
240
241         if (!($type == WO_ADVANCED))
242                 return add_work_order_quick($wo_ref, $loc_code, $units_reqd, $stock_id, $type, $date_, $memo_, $costs, $cr_acc, $labour, $cr_lab_acc);
243
244         begin_transaction();
245         $args = func_get_args();
246         $args = (object)array_combine(array('wo_ref', 'loc_code', 'units_reqd', 'stock_id',
247                 'type', 'date_', 'required_by', 'memo_', 'costs', 'cr_acc', 'labour', 'cr_lab_acc'), $args);
248         $args->woid = 0;
249         hook_db_prewrite($args, ST_WORKORDER);
250
251         $date = date2sql($date_);
252         $required = date2sql($required_by);
253
254         $sql = "INSERT INTO ".TB_PREF."workorders (wo_ref, loc_code, units_reqd, stock_id,
255                 type, date_, required_by)
256         VALUES (".db_escape($wo_ref).", ".db_escape($loc_code).", "
257         .db_escape($units_reqd).", ".db_escape($stock_id).",
258                 ".db_escape($type).", '$date', ".db_escape($required).")";
259         db_query($sql, "could not add work order");
260
261         $woid = db_insert_id();
262
263         add_comments(ST_WORKORDER, $woid, $required_by, $memo_);
264
265         $Refs->save(ST_WORKORDER, $woid, $wo_ref);
266         add_audit_trail(ST_WORKORDER, $woid, $date_);
267
268         $args->woid = $woid;
269         hook_db_postwrite($args, ST_WORKORDER);
270         commit_transaction();
271
272         return $woid;
273 }
274
275 //--------------------------------------------------------------------------------------
276
277 function update_work_order($woid, $loc_code, $units_reqd, $stock_id,
278                                         $date_, $required_by, $memo_)
279 {
280         begin_transaction();
281         $args = func_get_args();
282         $args = (object)array_combine(array('woid', 'loc_code', 'units_reqd', 'stock_id',
283                 'date_', 'required_by', 'memo_'), $args);
284         hook_db_prewrite($args, ST_WORKORDER);
285
286         $date = date2sql($date_);
287         $required = date2sql($required_by);
288
289         $sql = "UPDATE ".TB_PREF."workorders SET loc_code=".db_escape($loc_code).",
290                 units_reqd=".db_escape($units_reqd).", stock_id=".db_escape($stock_id).",
291                 required_by=".db_escape($required).",
292                 date_='$date'
293                 WHERE id = ".db_escape($woid);
294
295         db_query($sql, "could not update work order");
296
297         update_comments(ST_WORKORDER, $woid, null, $memo_);
298         add_audit_trail(ST_WORKORDER, $woid, $date_, _("Updated."));
299
300         hook_db_postwrite($args, ST_WORKORDER);
301         commit_transaction();
302 }
303
304 function delete_work_order($woid)
305 {
306         begin_transaction();
307         hook_db_prevoid(ST_WORKORDER, $woid);
308
309         // delete the work order requirements
310         delete_wo_requirements($woid);
311
312         // delete the actual work order
313         $sql = "DELETE FROM ".TB_PREF."workorders WHERE id=".db_escape($woid);
314         db_query($sql,"The work order could not be deleted");
315
316         delete_comments(ST_WORKORDER, $woid);
317         add_audit_trail(ST_WORKORDER, $woid, $_POST['date_'], _("Canceled."));
318
319         commit_transaction();
320 }
321
322 //--------------------------------------------------------------------------------------
323
324 function get_work_order($woid, $allow_null=false)
325 {
326     $sql = "SELECT wo.*,st.description As StockItemName,l.location_name,
327                 l.delivery_address,l.email, l.contact
328                 FROM ".TB_PREF."workorders wo, ".TB_PREF."stock_master st, ".TB_PREF."locations l
329                 WHERE st.stock_id=wo.stock_id
330                 AND     l.loc_code=wo.loc_code
331                 AND wo.id=".db_escape($woid)."
332                 GROUP BY wo.id";
333
334         $result = db_query($sql, "The work order issues could not be retrieved");
335
336         if (!$allow_null && db_num_rows($result) == 0)
337                 display_db_error("Could not find work order $woid", $sql);
338
339         return db_fetch($result);
340 }
341
342 //--------------------------------------------------------------------------------------
343
344 function work_order_has_productions($woid)
345 {
346         $sql = "SELECT COUNT(*) FROM ".TB_PREF."wo_manufacture WHERE workorder_id=".db_escape($woid);
347         $result = db_query($sql, "query work order for productions");
348
349         $myrow = db_fetch_row($result);
350         return ($myrow[0] > 0);
351 }
352
353
354 //--------------------------------------------------------------------------------------
355
356 function work_order_has_issues($woid)
357 {
358         $sql = "SELECT COUNT(*) FROM ".TB_PREF."wo_issues WHERE workorder_id=".db_escape($woid);
359         $result = db_query($sql, "query work order for issues");
360
361         $myrow = db_fetch_row($result);
362         return ($myrow[0] > 0);
363 }
364
365 //--------------------------------------------------------------------------------------
366
367 function work_order_has_payments($woid)
368 {
369         $result = get_gl_wo_cost_trans($woid);
370
371     return (db_num_rows($result) != 0);
372 }
373
374 //--------------------------------------------------------------------------------------
375
376 function release_work_order($woid, $releaseDate, $memo_)
377 {
378         begin_transaction();
379
380         $myrow = get_work_order($woid);
381         $stock_id = $myrow["stock_id"];
382
383         $date = date2sql($releaseDate);
384
385         $sql = "UPDATE ".TB_PREF."workorders SET released_date='$date',
386                 released=1 WHERE id = ".db_escape($woid);
387         db_query($sql, "could not release work order");
388
389         // create Work Order Requirements based on the bom
390         create_wo_requirements($woid, $stock_id);
391
392         add_comments(ST_WORKORDER, $woid, $releaseDate, $memo_);
393         add_audit_trail(ST_WORKORDER, $woid, $releaseDate,_("Released."));
394
395         commit_transaction();
396 }
397
398 //--------------------------------------------------------------------------------------
399
400 function close_work_order($woid)
401 {
402         $sql = "UPDATE ".TB_PREF."workorders SET closed=1 WHERE id = ".db_escape($woid);
403         db_query($sql, "could not close work order");
404 }
405
406 //--------------------------------------------------------------------------------------
407
408 function work_order_is_closed($woid)
409 {
410         $sql = "SELECT closed FROM ".TB_PREF."workorders WHERE id = ".db_escape($woid);
411         $result = db_query($sql, "could not query work order");
412         $row = db_fetch_row($result);
413         return ($row[0] > 0);
414 }
415
416 //--------------------------------------------------------------------------------------
417
418 function work_order_update_finished_quantity($woid, $quantity, $force_close=0)
419 {
420         $sql = "UPDATE ".TB_PREF."workorders SET units_issued = units_issued + ".db_escape($quantity).",
421                 closed = ((units_issued >= units_reqd) OR ".db_escape($force_close).")
422                 WHERE id = ".db_escape($woid);
423
424         db_query($sql, "The work order issued quantity couldn't be updated");
425 }
426
427 //--------------------------------------------------------------------------------------
428
429 function void_work_order($woid)
430 {
431         begin_transaction();
432         hook_db_prevoid(ST_WORKORDER, $woid);
433
434         $work_order = get_work_order($woid);
435         if (!($work_order["type"] == WO_ADVANCED))
436         {
437                 $sql = "UPDATE ".TB_PREF."workorders SET closed=1,units_reqd=0,units_issued=0 WHERE id = "
438                         .db_escape($woid);
439                 db_query($sql, "The work order couldn't be voided");
440
441                 // void all related stock moves
442                 void_stock_move(ST_WORKORDER, $woid);
443
444                 // void any related bank/gl trans
445                 void_bank_trans(ST_WORKORDER, $woid, true);
446
447                 // clear the requirements units received
448                 void_wo_requirements($woid);
449         }
450         else
451         {
452                 // void everything inside the work order : issues, productions, payments
453                 $date = sql2date($work_order['date_']);
454                 
455                 $result = get_work_order_productions($woid); // check the produced quantity
456                 while ($row = db_fetch($result))
457                 {
458                         void_work_order_produce($row['id']);
459                         
460                         //Post voided entry if not prevoided explicitly
461                         $void_entry = get_voided_entry(ST_MANURECEIVE, $row['id']);
462                         if ($void_entry)
463                                 continue;
464                         $memo_ = _("Voiding Work Order Trans # ").$woid;
465                         add_audit_trail(ST_MANURECEIVE, $row['id'], today(), _("Voided.")."\n".$memo_);
466                         add_voided_entry(ST_MANURECEIVE, $row['id'], today(), $memo_);
467                 }
468
469                 $result = get_work_order_issues($woid);
470                 $cost = 0;
471                 while ($row = db_fetch($result))
472                 {
473                         void_work_order_issue($row['issue_no']);
474                         
475                         //Post voided entry if not prevoided explicitly
476                         $void_entry = get_voided_entry(ST_MANUISSUE, $row['issue_no']);
477                         if ($void_entry)
478                                 continue;
479                         $memo_ = _("Voiding Work Order Trans # ").$woid;
480                         add_audit_trail(ST_MANUISSUE, $row['issue_no'], today(), _("Voided.")."\n".$memo_);
481                         add_voided_entry(ST_MANUISSUE, $row['issue_no'], today(), $memo_);                              
482                 }
483
484                 //Adust avg labour cost
485                 $cost = get_gl_wo_cost($woid, WO_LABOUR); 
486                 if ($cost != 0)
487                         add_labour_cost($work_order['stock_id'], 1, $date, -$cost, true);
488                         
489                 //Adust avg overhead cost
490                 $cost = get_gl_wo_cost($woid, WO_OVERHEAD); 
491                 if ($cost != 0)
492                         add_overhead_cost($work_order['stock_id'], 1, $date, -$cost, true);
493                 
494                 $sql = "UPDATE ".TB_PREF."workorders SET closed=1,units_reqd=0,units_issued=0 WHERE id = "
495                         .db_escape($woid);
496                 db_query($sql, "The work order couldn't be voided");
497
498                 // void all related stock moves
499                 void_stock_move(ST_WORKORDER, $woid);
500
501                 // void any related bank/gl trans
502                 void_bank_trans(ST_WORKORDER, $woid, true);
503
504                 // clear the requirements units received
505                 void_wo_requirements($woid);
506         }
507         commit_transaction();
508 }
509
510 function get_sql_for_work_orders($outstanding_only, $all_items)
511 {
512         $sql = "SELECT
513                 workorder.id,
514                 workorder.wo_ref,
515                 workorder.type,
516                 location.location_name,
517                 item.description,
518                 workorder.units_reqd,
519                 workorder.units_issued,
520                 workorder.date_,
521                 workorder.required_by,
522                 workorder.released_date,
523                 workorder.closed,
524                 workorder.released,
525                 workorder.stock_id,
526                 unit.decimals
527                 FROM ".TB_PREF."workorders as workorder,"
528                         .TB_PREF."stock_master as item,"
529                         .TB_PREF."item_units as unit,"
530                         .TB_PREF."locations as location
531                 WHERE workorder.stock_id=item.stock_id 
532                         AND workorder.loc_code=location.loc_code
533                         AND item.units=unit.abbr";
534
535         if (check_value('OpenOnly') || $outstanding_only != 0)
536         {
537                 $sql .= " AND workorder.closed=0";
538         }
539
540         if (isset($_POST['StockLocation']) && $_POST['StockLocation'] != $all_items)
541         {
542                 $sql .= " AND workorder.loc_code=".db_escape($_POST['StockLocation']);
543         }
544
545         if (isset($_POST['OrderId']) && $_POST['OrderId'] != "")
546         {
547                 $sql .= " AND workorder.id LIKE ".db_escape('%'.$_POST['OrderId'].'%');
548         }
549
550         if (isset($_POST['OrderNumber']) && $_POST['OrderNumber'] != "")
551         {
552                 $sql .= " AND workorder.wo_ref LIKE ".db_escape('%'.$_POST['OrderNumber'].'%');
553         }
554
555         if (isset($_POST['SelectedStockItem']) && $_POST['SelectedStockItem'] != $all_items)
556         {
557                 $sql .= " AND workorder.stock_id=".db_escape($_POST['SelectedStockItem']);
558         }
559
560         if (check_value('OverdueOnly'))
561         {
562                 $Today = date2sql(Today());
563
564                 $sql .= " AND workorder.required_by < '$Today' ";
565         }
566         $sql .= " ORDER BY workorder.id DESC";
567         return $sql;
568 }
569
570 function get_sql_for_where_used()
571 {
572         $sql = "SELECT 
573                         bom.parent,
574                         workcentre.name As WorkCentreName,
575                         location.location_name,
576                         bom.quantity,
577                         parent.description
578                         FROM ".TB_PREF."bom as bom, "
579                                 .TB_PREF."stock_master as parent, "
580                                 .TB_PREF."workcentres as workcentre, "
581                                 .TB_PREF."locations as location
582                         WHERE bom.parent = parent.stock_id 
583                                 AND bom.workcentre_added = workcentre.id
584                                 AND bom.loc_code = location.loc_code
585                                 AND bom.component=".db_escape($_POST['stock_id']);
586         return $sql;                    
587 }
588 //--------------------------------------------------------------------------------------
589 function get_gl_wo_cost($woid, $cost_type)
590 {
591         $cost = 0;
592         $result = get_gl_wo_cost_trans($woid, $cost_type);
593         while ($row = db_fetch($result))
594                 $cost += -$row['amount'];
595         return $cost;   
596 }
597
598 ?>