Disassembly can be used to break down inventory items into components. The disassembly function can only be used with items that have a Bill of Materials showing their component parts.

For items that are sold in singles and cases (e.g. Single Wine Bottle, 6-pack, 12-pack), and unit conversions, we recommend using the Additional Units of Measure function. This will better show the availability of the different configurations in the availability report. Functionally, it is identical to manual disassembly of a case of items into multiple single items. 

Disassembly is not available for inventory items with Type = Non-inventory.

By default, disassembly costs are split equally between component lines of the Bill of Materials. See Disassembly Costs to learn how to split costs differently. 


Table of Contents:

Create an item with a Bill of Materials

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The disassembly function can only be used with items that have a Bill of Materials showing their component parts. If you already have products with a Bill of Materials, skip to the next step. 

NOTE: To create a product with a Bill of Materials, the component products and services must already be created in DEAR.

To add a Bill of Materials to an item:

  1. When creating a new product or editing an existing product, check the Bill of Materials box in the document header.

  2. This activates the Bill of Materials tab below. Use + or Add more items to select the component products from your inventory.
  3. Enter the Quantity of each component product produced in the disassembly.
  4. Enter the Disassembly Cost percentage if required. See Disassembly Costs for more details.

  1. Service items associated with the disassembly can be included by clicking or Add more items to the Labour and Overheads section. It is required to include an Expense Account.

  2. Save the product.

Disassembly Costs

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When Disassembly Cost percentage is left blank on the Bill of Materials, DEAR splits the cost of the disassembled item equally between the component lines, as shown below. Note that the split is among component lines and ignores item quantity per line. The cost of the item to disassemble can be estimated using Average Cost, Last Supplier Price or Fixed Supplier Price. 

Use Disassembly Cost percentage to split this differently.


Product A has $100 cost, and is disassembled into:

  • 2 x Product X
  • 1 x Product Y

By default, both component lines would be calculated as $50. Product X, with a quantity of 2 items, will be calculated at $25 while Product Y will be $50. 

You want to calculate each Product X item as $10 while Product Y is $80. Your disassembly cost percentage should be 20% (2 x %10) for the Product X line and 80% for the Product Y line. 

Disassemble an item

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Disassembly can be performed manually or automatically. Auto-disassembly is only recommended in the case where you do not sell the assembled product.

To disassemble an item manually:

  1. Navigate to Production -> New -> Disassembly.
  2. Choose the Location where the disassembly will take place.
  3. Choose a product from the dropdown menu. Only products with a Bill of Materials will be shown.
  4. Choose a Work in Progress account. 
  5. Enter a Quantity to disassemble. Use Maximum Quantity to calculate the maximum number of disassemblies that can be performed with your available inventory.
  6. You can also enter an optional Completion Date and Notes.

  7. Next, in the Pick tab, click Auto-Pick to automatically choose the items to disassemble from your inventory.
  8. Click Authorise.

  9. In the Result tab, click Load BOM to see the component products produced from the disassembly and their costs. Quantity, Work in Progress account, Costs and Labour & Overheads can all be manually adjusted if the final value differs from the BOM value. 
  10. Click Complete to finish.


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Auto-disassembly is triggered once Stock Received has been authorised for a purchase order. 

NOTE: Only FIFO, FIFO-Batch and Special-Batch costing methods support auto-disassembly.

To disassemble an item automatically:

  1. Navigate to Inventory -> Products.
  2. Select the product you wish to disassemble automatically.
  3. Check the Auto-disassembly box.
  4. Save the product.

When this item is received into the inventory, a disassembly task will automatically be created and completed. It is not possible to manually alter the results of a disassembly when auto-disassembly is selected.

View Disassembly List

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You can view all historical Disassemblies by navigating to Production -> Disassemblies

See the details of previous disassemblies by clicking on each line.

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