Assembly Orders are a subset of Inventory Planner's Bundles & Assemblies planning functionality. Learn more about how Bundles and Assemblies work together to recommend what to produce (Assembly Orders) and what to order from Vendors (Purchase Orders) here: Bundles & Assemblies
Configuring Assemblies & Assembly Time
Assemblies Replenishment: Assembly Orders (produce Assemblies)
Create Assembly Orders
An Assembly must be produced from components (variants) before it can be placed into stock and available for sale. These goods are pre-assembled before the sale and fulfillment of an item.
Assemblies include any produced goods with a bill-of-materials (BOM), and bundles/kits that must be produced before sending to Amazon (or a different fulfillment warehouse). All bundles associated with FBA are considered Assemblies - since Amazon only carries finished goods/produced bundles.
Note: Inventory Planner does not allocate component stock for the production of assemblies at Amazon FBA, since it is not possible to assemble stock at an FBA warehouse. Only transfer recommendations of completed Assemblies can be configured for an FBA warehouse. For Assembly Order recommendations (production orders), configure a combined warehouse using sales from Amazon with stock from FBA + another warehouse where assemblies can be produced.
Configuring Assemblies & Assembly Time
To configure Assemblies with existing Variants (or IP Variants), you can follow the exact same instructions as above for “Configuring Bundles.”
The main difference in this configuration is for eCommerce stores and/or Marketplace connections. No external app is needed in this case to manage stock of Assemblies and component variants based on their respective sales - since the stock of Assemblies and components is managed separately on your connected platform, by definition.
Another key difference with Assemblies is that Assembly Time must be considered in order to create Assembly Orders. To update Assembly Time:
From Replenishment, select Assemblies using the top left dropdown;
Configure ‘Assembly Time’ as the time it takes to produce new assemblies if/when component stock is available. Create new Assembly Orders based on recommendations, and see incoming stock in Replenishment as ‘On Assembly’.
Note: if nested assemblies are used (eg. 10 Pack Cookies > Cookies > Flour), then Assembly Time for each is based on time to assemble from the oldest connected child component (eg. 1 day to assemble 10 packs using single cookies, 5 days to assemble new cookies using flour)
Component Variant Lead Times are configured using the ‘Variants’ view in Replenishment. They will be pulled into the ‘Assemblies’ view automatically, and considered in the replenishment analysis for new Assemblies (above & beyond what can be assembled from existing component stock).
As purchase orders and/or assembly orders are received in Inventory Planner (used only when purchase orders and assembly orders cannot sync to your platform), Inventory Planner offers an optional step to increase or decrease the stock levels for Assemblies and component Variants in your store accordingly. Learn more about how Inventory Planner can optionally adjust stock in your store after receiving orders.
You can enable Bundles and Assemblies By default under your Account Settings to apply this setting storewide.
Assemblies Replenishment: Assembly Orders (Produce Assemblies)
Before purchasing new component stock, you can create new Assembly Orders to use existing component stock based on the recommended ‘Next To Assemble’ quantity.
The Replenishment quantity for Assemblies is the ‘Next To Assemble’ quantity + the additional replenishment needed to satisfy forecasted sales during the Days of Stock period. If there is not enough existing component stock to assemble any new assemblies, the ‘Next to Assemble’ quantity will be the same as the Replenishment quantity.
In Replenishment and Edit Forecast, select Assemblies view;
Select the ‘Details’ icon;
Select the ‘Bundles & Production’ tab to see component variants and details related to the Assembly in view.
Note: clicking the ‘details’ icon next to components in this screen opens a new tab displaying Replenishment, filtered on the component variant.
Select the Replenishment & Forecast tab to see forecasted needs and replenishment recommendations for the Assembly. Learn how Forecasts and Replenishment are calculated here.
Hover your cursor over the Forecast Stock chart and the ‘To Assemble’ rows of the left-hand table to view a recommended assembly schedule, based on your configured Assembly Time and component Lead Times.
In this example, only 5 Assemblies can be assembled in the immediate term (since the current stock = 5 of ‘Table Top Large’). If new components are ordered today, we can assemble 332 additional tables once the new components arrive to meet the total Replenishment of 337.
Select “Show Forecast Stock for Components” to see how Assemblies replenishment impacts component variant stock.
Quantities ordered using an Assembly Order are represented in the “On Assembly” column in Replenishment (below in blue). Use the purple gear icon in the top right corner to adjust columns.
After creating a new Assembly Order, the remaining quantity “Next To Assemble” is equivalent to the “Replenishment” recommendation (below in orange). This is the recommended quantity to assemble once new components are ordered and received from the Vendor.
Component Lead Times are considered automatically when Inventory Planner calculates the time it will take for new components to arrive (14 days in this example; Nov 22 - Dec 6), then produce new Assemblies (7 days in this example; Dec 6 - Dec 13).
The remaining quantity to replenish and assemble is thus based on the Days of Stock configuration (30 days in this example; Dec 13 - Jan 12), as this defines the true window of time where sales can be captured. This sequence is circled below in (red).
Create Assembly Orders
From the main Replenishment screen with ‘Assemblies’ selected - Configure the Assembly Time as the time it takes in days to produce new Assemblies from existing component stock. This defines the ‘expected date’ for assembly orders. Select relevant Assemblies then “+ New Assembly Order” to create a new Assembly Order using existing component stock.
A new Assembly Order is generated. The same source and destination warehouse is selected by default - since assembly/production tends to take place in a single location.
Select the ‘Components’ button in the Assembly Order to see the components required to meet the quantity listed in the Assembly Order.
Check for errors with the (!) button in the top right and make adjustments as necessary. The "Limit to source stock" feature reduces the number of Assemblies based on the available stock of component variants at the source warehouse.
Once an Assembly Order is saved, you will find it in the Purchase Orders & Transfers section of Inventory Planner. Add Filter on Type = ‘Assembly' to see Assembly Orders.
Note: Similar to how the Purchase Orders and Transfer Orders functions work, some systems support the ability to save Assembly Orders from Inventory Planner to the connected system - to manage order receiving and stock changes directly in the IMS. If your integration supports the “Push Assembly Orders” feature, an option will appear after creating the Assembly Order to ‘Save to (your system)’. Visit the Integrations Page to see if your connection supports this feature.
Once new assemblies are fully produced, you can Receive the Assembly Order* and select ‘Save’ to apply the receipt. This action closes the order and zeroes the “On Assembly” quantity in Replenishment.
*Note: Assemblies can only be received in Inventory Planner if they have not been saved to external connection.
After receiving an assembly order, options appear to increase stock of Assemblies in your store and to decrease stock of component variants respectively. Learn more about receiving inventory and pushing inventory to your store.
Select the respective Assembly or Variant to adjust stock for, then ‘Update Selected’ to complete the stock level change.