Overview

When actual production uses fewer raw materials than the Bill of Materials planned for — due to yield variation, a shorter run, or careful production — Luminous gives you two clear options depending on when you catch the discrepancy: before or after you complete the assembly order.

Luminous only deducts the Actual Qty from inventory when an assembly order is completed — not the Planned Qty. If you update actual quantities before saving the order as Complete, any unused material stays in inventory automatically.

Step A — Reduce the Actual Quantity (finished-good yield)

  1. Open the assembly order (Inventory → Assembly Orders, or from the work order sidebar).
  2. In the Actual Quantity field (header section), enter the number of finished goods actually produced.
  3. Component lines that use Actual consumption basis will scale down proportionally — for example, if you produced 90 % of planned yield, those components will consume 90 % of their BOM quantity.
  4. Component lines that use Planned consumption basis stay at the fixed BOM quantity regardless of yield (e.g., labels, boxes).

See Configure assembly order consumption basis (Planned vs Actual) for a full explanation of each basis type.

Step B — Override individual component lines (if needed)

If a specific component (especially a Planned-basis material) was used in a smaller quantity than the BOM specifies:

  1. In the component table on the assembly order, locate the row for that material.
  2. Edit the Actual column for that line to reflect the quantity actually consumed.
  3. Repeat for any other components with leftover material.
  4. The remaining on-hand balance for those materials will be unchanged at completion.

Step C — Complete the order

Once all actual quantities are accurate, set the status to Complete and save. Luminous deducts each component's Actual Qty from on-hand inventory and adds the finished goods.

Option 2: After the assembly order is already completed — create a Disassembly Order

If the assembly order has already been marked Complete and raw materials were over-consumed, use a Disassembly Order to reverse the transaction.

A disassembly order:

  • Deducts the finished goods from inventory.
  • Returns the component raw materials to on-hand inventory.

Steps

  1. Go to Inventory → Assembly Orders.
  2. Click Create → Create Disassembly Order (or navigate to the disassembly creation screen).
  3. Select the finished-good SKU and the BOM.
  4. Enter the quantity to disassemble.
  5. Verify the component quantities that will be returned to inventory, then save.
  6. Set the status to Complete to post the inventory reversal.

After disassembly, the correct quantity of finished goods and raw materials will be reflected in inventory. You can then create a new assembly order if needed for the remainder.

Option 3: Cycle Count (minor discrepancy reconciliation)

If the over-consumption was small and you do not need to adjust finished-good inventory, you can reconcile the raw material balance directly with a cycle count:

  1. Go to Inventory → Cycle Counts.
  2. Count and submit the correct on-hand quantity for the affected raw material SKU.
  3. Luminous will adjust on-hand to match the counted quantity.

Use this approach cautiously — it adjusts inventory without documenting the production context.

Quick reference: which option to use?

SituationBest approach
Assembly order is still open / not yet completedReduce Actual Qty on the order (Option 1)
Assembly order is complete; you need to fix finished-good and component countsCreate a Disassembly Order (Option 2)
Assembly order is complete; small raw-material count discrepancy onlyCycle Count (Option 3)