This article explains how Buffer Orders function within Sync, why they are created, and the impact they have on production units.


TABLE OF CONTENTS


Overview

Buffer orders are internal finished goods orders used to:

  • Determine total unit quantities for production before any sales orders are loaded for a job, or

  • Amend total unit quantities for production after sales orders are loaded for a job.

Buffer orders play a critical role in calculating the quantities of fabric and trims required for locally manufactured styles. By defining production quantities upfront (or adjusting them later), they directly influence material planning and procurement.

Important:
A job product can only be linked to one buffer order.


Buffer orders provide structured control over total production quantities. They allow businesses to:

  • Plan manufacturing ahead of confirmed sales

  • Adjust production strategically after demand is known

  • Improve material planning accuracy

  • Maintain tighter control over production unit totals

Understanding when and how to use buffer orders ensures accurate production planning, controlled inventory levels, and efficient material procurement.


Sales Order vs Buffer Order in Sync

Understanding the difference between Sales Orders and Buffer Orders in Sync is essential before creating buffer orders.


Sales Orders

A Sales Order represents a customer’s purchase order for a style. It specifies:

  • Required quantities per product and size combination

  • Selling price per product

  • Required delivery date

Key Principles of Sales Orders

  • Once a sales order is loaded against a product, the only way to amend production units for that job is via the sales order.

  • The sum of all sales order units (per product and size combination) determines the total production units for a job — as long as no approved buffer order exists.

  • Any addition, amendment, deletion, or cancellation of a sales order directly impacts production units.

In short, without a buffer order, production quantities are entirely driven by customer demand.


Buffer Orders

A Buffer Order is an internal production planning tool. It:

  • Specifies projected production quantities per product and size combination

  • Does not represent a customer order

  • Does not specify a customer or sales representative

  • Does not need to be fulfilled or invoiced

Buffer orders exist purely to control production quantities.


How Buffer Orders Impact Production Units

The timing of when a buffer order is added determines how it affects production.


Adding a Buffer Order Before Sales Orders

Purpose

To set total production quantities upfront before any sales orders are loaded.


What Happens

  • The buffer order determines the total job production units.

  • Sales orders added later will reduce the buffer order quantity by the number of units on the sales order.

  • Total production units remain unchanged unless the buffer order itself is amended.


Production Scenario

Finished goods are produced first and then sold.


Example

If a buffer order sets production at 1,000 units:

  • A later sales order for 300 units reduces the buffer order to 700 units.

  • Total production remains 1,000 units.

This allows production planning and material procurement to begin before confirmed sales.

Adding a Buffer Order After Sales Orders

Purpose

To increase or decrease total production quantities after demand has been determined through pre-book sales.


What Happens

  • Sales orders initially determine total production units.

  • When a buffer order is added afterward, it adjusts (increases or decreases) total job production units based on the quantities loaded in the buffer order.


Production Scenario

Pre-book sales determine demand first. Production quantities are then adjusted strategically.


Example

If sales orders total 800 units, and a buffer order of 200 units is added:

  • Total production increases to 1,000 units.

Alternatively, the buffer order could reduce production if necessary.


Amending a Buffer Order

To amend total production quantities on a job:

  • The buffer order must be deleted and re-added

  • The new buffer order must be approved

Buffer orders cannot simply be edited — they must be recreated to change production totals.


Operational Impact on Production Units

Buffer orders affect several production planning areas:


1. Material Planning

  • Determines required fabric and trims

  • Drives procurement quantities

  • Prevents under-ordering or over-ordering


2. Production Capacity Planning

  • Defines total units to be manufactured

  • Impacts factory scheduling and timelines


3. Inventory Strategy

  • Supports make-to-stock models (produce first, sell later)

  • Allows strategic overproduction for anticipated demand


4. Sales Flexibility

  • Enables pre-production without confirmed orders

  • Allows controlled adjustment of production volumes after demand is known


USEFUL LINKS:
How to Create a Buffer Order

How to Create a Negative Buffer Order