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