Lesson 4 of 5 · 10 min read
Lab: Producing a mango juice batch
A hands-on walkthrough in the Oasis Fresh (Saudi) demo BG. You'll review a formula, create a job order for 10,000 bottles of mango juice, issue materials, complete production, record scrap, and watch the cost flow from raw material → WIP → finished goods. Pearl F&B (Qatar) and Nile Foods (Egypt) run the same flow in QAR and EGP respectively.
Before you start
Open the demo in a new tab:
- URL: https://aion-erp.vercel.app
- Username:
admin - Password:
Admin123
Your mission: Produce 10,000 bottles of Oasis mango juice 500ml. Follow the cost from raw materials into WIP, then into finished goods inventory.
Estimated time: 10 minutes.
Step 1 — Review the formula
Navigate to: Manufacturing → Formulas
Find the Mango Juice 500ml formula. Open it.
You should see the ingredient list (water, mango concentrate, sugar, citric acid, preservative) with percentages. Check the status — it should be Approved v1.0.
This is the recipe. It has a version, an approver, and a locked set of ingredients. A change requires a new version and re-approval.
Step 2 — Review the BOM for a 10,000-bottle batch
From the formula screen, click Generate BOM → 10,000 bottles. AION computes the exact quantities:
| Item | UoM | Qty |
|---|---|---|
| Mango concentrate 65° Brix (RM-001) | L | 750 |
| Refined sugar (RM-003) | kg | 200 |
| Citric acid (RM-004) | kg | 15 |
| PET bottle 500ml (RM-005) | pcs | 10,000 |
| (Additional components auto-filled from formula) | — | — |
Save the BOM as a template for future batches.
Step 3 — Check material availability
Navigate to: Manufacturing → Planning → Availability Check
Enter the BOM. AION shows:
- Required vs. on-hand for each material
- Shortages (if any) with recommendation to create purchase requisitions
For this lab, the demo has seeded sufficient inventory. Proceed.
Step 4 — Create the job order
Navigate to: Manufacturing → Job Orders → New
Fill in:
- Product: FG-001 Oasis Mango Juice 500ml
- Quantity: 10,000 pcs
- Formula version: v1.0 (locked from the formula)
- Planned start: today
- Planned end: today + 1 day
- Cost center: Bottling Line 2
Save. Note the job order number — something like JO-2026-00123.
Release the job order. This:
- Reserves the required raw materials in inventory (they can’t be picked for another job)
- Creates the empty WIP bucket for this batch
- Locks the formula version
No GL impact yet. Materials haven’t physically moved.
Step 5 — Issue materials
Navigate to: Manufacturing → Material Issues → New
Select JO-2026-00123. The issue screen pre-populates the required quantities. For each material, AION suggests a lot (FEFO).
Confirm the lots (for mango concentrate, you should see MAN-2026-0512-EGY from the P2P lab — or another lot from seeded data).
Save and post the issue.
GL impact — automatic (for each material line, summed):
| Account | DR | CR |
|---|---|---|
| 1210 Work in Process | ~18,500 SAR (sum of all materials at period avg cost) | |
| 1200 Raw Material Inventory | 18,500 SAR |
Exact total depends on seeded costs. Typical for a 10K-bottle mango batch: concentrate dominates (~14,000), sugar ~1,500, bottles ~2,500, other ~500.
Check it: Trial Balance → accounts 1200 and 1210. Raw material inventory dropped; WIP grew by the same.
Step 6 — Record completion
After production is done (simulated — the demo doesn’t make you wait 24 hours), navigate to: Manufacturing → Completions → New
Fill in:
- Job order:
JO-2026-00123 - Produced quantity: 9,850 bottles (yielded 98.5% of target; the other 150 went to scrap)
- Lot assigned to FG: auto-generated, something like
FG-001-2026-0617-A - Expiry date: 6 months out (default for mango juice)
Save and post.
GL impact — automatic:
| Account | DR | CR |
|---|---|---|
| 1220 Finished Goods Inventory | ~18,200 SAR (9,850 units × standard cost ~1.85 SAR) | |
| 1210 Work in Process | 18,200 SAR |
Step 7 — Record scrap
150 bottles failed QA. Navigate to: Manufacturing → Scrap Entries → New
Fill in:
- Job order:
JO-2026-00123 - Quantity: 150 bottles
- Reason: Filler under-fill
Save.
GL impact — automatic:
| Account | DR | CR |
|---|---|---|
| 5200 Manufacturing Variance — Scrap | 280 SAR (150 × 1.85) | |
| 1210 Work in Process | 280 SAR |
Step 8 — Close the job order
Navigate to JO-2026-00123 and click Close Job Order.
AION reconciles:
- Total actual materials issued: 18,500 SAR
- Total applied (FG completed + scrap): 18,200 + 280 = 18,480 SAR
- Variance: 20 SAR under-applied (actual > applied)
GL impact — automatic:
| Account | DR | CR |
|---|---|---|
| 5210 Mfg Variance — Yield | 20 SAR | |
| 1210 Work in Process (clearing) | 20 SAR |
WIP balance for this job: zero. The 20 SAR variance sits in the P&L for analysis.
Step 9 — Trace the lot (the magic moment)
Navigate to: Inventory → Lots → FG-001-2026-0617-A
Click Where Used (Backward). You’ll see:
- Made in job order
JO-2026-00123 - Which consumed raw material lots:
MAN-2026-0512-EGY(mango concentrate), sugar lot, citric lot, etc. - Those lots originally came from specific PO receipts and specific suppliers
This is your recall audit trail. In 5 seconds you know exactly which raw material lots went into any finished good lot.
Verify the full picture
Net impact across all steps for this job order:
| Account | Net |
|---|---|
| 1200 Raw Material Inventory | −18,500 |
| 1210 Work in Process | 0 (opened at issue, closed at completion + scrap + variance) |
| 1220 Finished Goods Inventory | +18,200 |
| 5200 Mfg Variance — Scrap | +280 |
| 5210 Mfg Variance — Yield | +20 |
The variances land in the P&L (we can see how much margin was lost to scrap and yield deviations). The finished goods are in stock, ready to sell. The raw material is consumed.
Every step is a balanced journal entry. Every entry posted automatically.
What would have been different with Excel
- Materials tracked on paper pick lists; issues reconciled monthly
- Completion recorded on a spreadsheet; WIP balance is imaginary
- Scrap often not recorded at all
- Standard cost used for FG is the only cost; no variance visible
- Lot traceability: 3-4 hours per recall query, and only if the right person is in the office
That’s the gap. Next lesson turns it into numbers.
Also runs in Pearl F&B (Qatar) and Nile Foods (Egypt)
The same production flow runs across all three demo Business Groups — same recipe structure, different cost basis per BG (driven by local raw material prices, packaging costs, and currency).
| 🇸🇦 Oasis Fresh (Saudi) | 🇶🇦 Pearl F&B (Qatar) | 🇪🇬 Nile Foods (Egypt) | |
|---|---|---|---|
| Currency | SAR | QAR | EGP |
| Featured FG | Oasis Mango Juice 1L (std cost SAR 10.5) | Pearl Mango Juice 1L (std cost QAR 9.2) | Nile Guava Juice 1L (std cost EGP 36) |
| Featured raw | Mango concentrate (drum, SAR 42/kg) | Mango concentrate (drum, QAR 38/kg) | Egyptian mango concentrate (EGP 145/kg) |
| CFO login | cfo.saudi | cfo.qatar | cfo.egypt |
The BOM rollup logic is identical across BGs. Cost variances (material usage, labor efficiency, overhead) post to the same SLA-driven journals. The difference is the cost basis — Egyptian local concentrate is cheaper per kg than imported Saudi concentrate, but the finished good sells at higher prices to local distributors.
Try the same lab in another region:
Next lesson
In Lesson 5 — Cost flow & GL impact, we’ll look at the complete cost flow, the variance analysis reports, and the ROI of running P2M properly.