Costing >  Cost calculations >  Simulated cost calculation  

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This function is used to calculate the simulated cost of a product, a selection of products, all the products at a site from a cost type routing alternative, a cost type BOM, with or without immediate update, to print a document summarizing or detailing the calculation.

The simulated cost is generally used in order to prepare a cost estimation as a function of the project (new BOM, new component, new route).
The simulated cost calculation uses the routing data (time) and the valuation dimension data for the work centers associated with the route during the processing.

When the calculation is carried out a raw material, the process makes an attempt to determine the receipt overheads for the material.

The user has several possibilities available for the calculation to establish a simulated cost :

  • a choice of calculation quantities,
  • a choice of raw material valuation,
  • overheads,
  • the valuation dimension rates,
  • a posting method for the fixed costs.

For a calculation including the BOM multi-levels or for a calculation for several products, the process is exclusive by site, that is to say no other user can launch a cost calculation at the same site at the same time.

If the process is requested for a selection of products, the system examines these products in decreasing order of the codes at the lowest level.

The calculation with or without the lower BOM levels consists of reading the component costs at the first level and transferring them to the cost of the parent product.

  • When calculated with BOM split, the calculation includes the component costs at the first level, but also all components n decreasing order of the codes at the lowest level.
  • A calculation excluding the lower BOM is justified for an update when the costs of the sub-levels have already been calculated. 

 

Notes about the material and subcontract cost: :

  • Materials:
     
    By definition, material does not have component. The "Material cost selection" field is used to determine how its cost is calculated when defined as "calculated" and not "entered".
     
  • Subcontract:
     
    The search to value the sub-contract service in a context of production is as follows:
     
    1/ The reference price on the operation, if it exists, is taken into account.
    2/ The price of the valuation method is taken into account if valuation method is on the product-site.
    3/ Search of price list.
     
    The cost of materials given by a subcontract always comes from the price list; if the price list is not found, the standard cost can be used if the PURPRICE - Standard cost default price list parameter has the value Yes.
     
    To search the sub-contracting service (without WO) and the provided material list prices given by the subcontractor (and to search the material list price and the choice of BOM components), the calculation process is systematically based on the validity start date of the cost.

SEEWARNING If a product has a BOM, the production overhead is taken into account, otherwise the receipt overhead is taken into account.

Prerequisite

SEEREFERTTO Refer to documentation Implementation

Screen management

The Simulated cost calculation function is made up of a screen where the operator indicated the product selections and calculation parameters.

Entry screen

Presentation

Selection criteria

Site

The user must indicate the site for the calculation.

Selection of the products

The user must indicate either a product, or a group of products at the site or a selection of products.
When the choice is a single product, it is necessary to indicate the product reference, and to tick the box "unique".

  • To choose to calculate the simulated cost for all the products at the site, tick the "All" box.
  • To carryout the simulated cost calculation for a selection of products, it is necessary to create the selection filter via the contextual menu accessible in the Product field.

The filter can be saved.
At the end of the selection the "selection" button activates.

Validity

The user has to specify the validity period of the calculated revised standard cost.

Calculation quantity

This is the quantity that will be used in the calculation.
In the case of a calculation for a single product, this filed is loaded by default by the economic quantity for the product but can be modified.

Calculation parameters

BOM routings

The user must indicate an alternative routing of the cost type, this alternative must be associated with a BOM alternative that is also of the type cost.
In the case where the routing alternative is not entered, the process will only calculate the material costs.

BOM code

The BOM alternative is displayed and is non modifiable. This is the first BOM alternative associated with the routing alternative previously entered.
It is necessary to ensure that this BOM is of a cost type alternative.

Descent through the BOM

The "Descend BOM" field is only active in the case of a single product calculation.
If this flag is set, the process descend through the BOM to the lowest level or up to a parent product whose "Update Simulated Cost" code is entered (Cost tab in the product-site record).
The calculation process, stores the simulated cost for each parent product found.
If the flag is not positioned, the calculation is carried out at the first level, and it uses the existing costs of the components based on the material cost selected.

Distribution of the fixed costs

The fixed overheads (material loss, setup rate, operation loss rate, fixed rate) are distributed either as a totality or pro rata for the calculation quantity/economic quantity.

Material cost choice

The material cost choice is initialized by default (CLCBUDMAT setup), it is used to value the material cost.

Dimension rate choice

The dimension rate choice is initialized by default (CLCBUDRAT setup), it is used to value the labour and machine elements in the calculation.

OH column choice

The OH column choice (Overheads) is initialized by default (OVECOLBUD setup), it is used to value the overhead element in the calculation, detailed by the nature of the overhead and calculated by applying the fixed rate or the formula in the chosen calculation column.

Update code

The update code is used to :

  • Simulate a calculation (Choice 'no')
  • update the calculation in differed mode, this update is carried out by the "Update the calculated costs" function,
  • update immediately.
Printing the result of the calculation

At the end of the process, a log file can be printed, this file summarized all the products processed and any anomalies found.
A Crystal Report document can then be printed detailing and / or summarising the calculation.
When a calculation does not include a descent through the BOM, the print is of a calculation summary.

Close

 

Fields

The following fields are present on this tab :

Block number 1

Use this field to define the storage site (warehouse).

The site defined on the user record is displayed by default but can be amended.

A storage site has the check box Stock (Details tab) selected.

Product

  • field TOUS

Use this radio button to select records to be updated.

  • Unique. To update one specific record.
  • All. To update all records.
  • Selection. To select records using a calculation formula or filters.

Use this field to specify the product code to be updated.

  • Formula (field FILART)

Enter, select or build an Sage X3 filter calculation expression using the formula editor.

 An error message is displayed if you refer to tables which are not generally used by the configurator, or to unknown variables.

 This field is only available if the Selection radio button is selected.

 
  • Major version (field ECCVALMAJ)

Use this field to indicate which major version of this product applies. Major versions might be used where there have been increased or significant changes to the original or previous version, that is the 'form, fit or function' has changed.

Type in, or select a version code from the list of version codes displayed. This field is not available for entry if the product code defined in the Product field is not version managed.

  • Minor version (field ECCVALMIN)

Use this field to indicate which minor version of this product applies. Minor versions might be used where there have been minor features or changes in functionality, or significant fixes applied to a specific major version.

Type in, or select a version code from the list of version codes displayed. This field is not available for entry if the product code defined in the Product field is not version managed.

  • Calculation quantity (field CLCQTY)

Use this field to define the quantity to be included in the calculations. This field is only available if a product code has been defined. The default quantity is the Economic order quantity (field EOQ (REOMINQTY)) defined on the product-site record or the Technical lot (field MFGLOTQTY) defined on the product-site record, or 1.

This field displays the unit in which the product is stored. It provides the key to prices, costs, volumes etc.

Validity

  • Fiscal year (field FIYNUM)

Enter the number of the required fiscal year. A blocking message is displayed if a fiscal year not closed has been entered.

  • Start (field ITCSTRDAT)

The Fiscal year Start and Fiscal year End fields automatically indicate the start and end dates of the fiscal year. You cannot modify these dates.

Block number 4

  • Date calculated (field ITCDAT)

Cost calculation date. The default calculation date is today's date but can be changed. The defined date is written to the applicable Products-costs record.

 Only those components in a bill of materials (BOM) valid on this date are included in the calculations.

 This date must fall between the start and end dates of the defined Fiscal year (fields Start (field ITCSTRDAT) and End (field ITCENDDAT)).

  • BOM type (field BOMALTTYP)

Select Manufacturing if you manufacture this bill of materials (BOM); if it is procured from a subcontractor, select Subcontracting.

Multiple routings can be defined for a single product. Each routing code can be assigned specific management features. These include restriction of the routing to a specific site and to specific areas of functionality (for use in a manufacturing environment, for costing or for capacity planning). Use this field to define the route for the calculation of the components, machines, resources, workforce and subcontractors.

From this routing code, the program searches for the first valid alternative bill of materials (BOM) for the defined site. If you leave this field blank, only a material calculation can be made (valuation and calculation of material overheads).

Multiple bills of materials (BOMs) can be defined for a single product. Each BOM code can be assigned specific management features. For manufactured or subcontracted products this includes restriction of the BOM to a specific site and to specific areas of functionality (for costing or for capacity planning).

  • Calculate all BOM levels (field DESCEND)

The Calculate all BOM levels check box is only active for a single product calculation.

  • If this check box is selected, the cost calculation process descends through the bill of materials (BOM) to the lowest level, or up to a parent product whose 'Standard cost update' in their product-site record is entered. The cost calculation thus starts from the lower components. The standard cost of each component at each level will be calculated and stored, and the report will then be detailed.
     
  • If this check box is clear (not selected), the calculation is performed at the first level, from the standard costs of the components of the calculated products. This also applies if the calculation is launched for multiple products.

SEEINFO By definition, a material does not have to be a component. The Material cost selection field is used to determine how its cost is calculated when defined as 'Calculated' and not 'Entered'.

Block number 5

  • Fixed costs distribution (field FXDCSTDSP)

Use this field to define how the fixed overhead costs (material loss, setup rate, operation loss rate, fixed rate) are to be distributed.

  • Prorata. The fixed costs will be multiplied by the Calculated product quantity/Economic lot quantity combination.
  • Total. The total fixed cost will be posted.

  • Material cost (field SLTMATCST)

Use this field to define the type of cost to be used to value materials. The default cost type is defined in the CLCxxxMAT-Mat cost selection xxx calc parameter (TC chapter, COS group), where xxx corresponds to the type of cost calculation being performed (budget, standard, revised standard, simulation). You can change the default cost type, if required. The possible values are:

  • Standard cost,
  • Revised standard cost
  • Budget cost,
  • Simulated cost
  • Last cost. This value corresponds to the cost of the last recorded movement.
  • Average cost
  • Last purchase price. This value corresponds to the last receipt price or last invoice.
  • List price. The material is valued from a price list of the type priority supplier/product.

SEEINFO The selection of the cost type only applies to the cost calculation of a material (component without a valid BOM for the alternative). The cost of a product with a BOM is calculated based on the cost of its components. The cost of materials from a subcontractor always comes from a price list. If the price list is not found, the standard cost can be used if the PURPRICE - Standard cost default price list parameter is set to 'Yes'.

  • Dimension rate (field VLTCCERAT)

Use this field to define the dimension rate to be used to value time. The default cost type is defined in the CLCxxxRAT-Dimension rate selection xxx calc parameter (GPA chapter, COS group), where xxx corresponds to the type of cost calculation being performed (budget, standard, revised standard, simulation). You can change the default dimension rate, if required.

  • Overhead column (field SLTOVECOL)

Use this field to define how overheads are valued. The default column is defined in the OVECOLxxx-xxx calc overhead column parameter (GPA chapter, COS group), where xxx corresponds to the type of cost calculation being performed (budget, standard, revised standard, simulation). You can change the default column, if required.

The value of an overhead is calculated by applying the fixed rate or the formula in the chosen calculation column.

Update

  • field FIL6

 

  • Update (field MAJ)

Use this field to control any postings to the products-costs records.

  • No. The products-costs records are not updated.
  • Deferred. The update can be deferred and posted using the Calculated cost update function.
  • Immediate. The products-costs records are updated immediately upon completion of the calculation run.

  • Replace previous cost (field RPLPRVCST)

When a standard cost is updated immediately, a new sequence is created. Click this check box to replace the cost created previously with the same validity period (start and end date).

Close

 

Batch task

This function can be run in batch mode. The standard task CALCSTSIM is provided for that purpose.

Error messages

In addition to the generic error messages, the following messages can appear during the entry :

During the selection entry, the following messages may appear:

Site... Record non-existent

This message appears after the site entry if the corresponding record is not found. You can check this by using the selection window.

Product-site record does not exist ...

This message appears after the entry of the product reference if the corresponding record has not been found. You can check this by using the selection window.

Calculation prohibited: the Entered/calculated code is 'entered'

This message appears after the entry of the product reference if for this product in this site, the 'Entry/calculated' code corresponding to the function in process is set to 'Entered': this means that the data can not be overwritten by a calculation.

The cost exists already, it will be erased on the calculation update

This message appears after the modification of a product reference, for the site or for the year for the standard or simulated type calculation if this cost already exists. This is a non blocking warning.

If one of the costs corresponding to these selections exists already, it will be erased on the update of the calculation.

This message appears in the same cases as the previous message but for a calculation on a selection or for all the products.

Code not valid for this site!

This message appears after the entry of the alternative if this is dedicated to another site.

No BOM alternative is valid for the selected site

This message appears after the entry of the alternative if none of the 3 associated BOM alternatives is not dedicated to the site entered.

No BOM alternative found

This message appears after the selection entry if, for the product entered, no BOM exists after the search in the 3 alternative associated with the routing alternative.

No routing alternative : Warning material calculation only !

This message appears if the routing alternative is set to zero : only the material cost can be valued because no operation can be processed and no BOM can be read.

The filter must be constructed from the previous field (contextual menu)

This message appears after having ticked the radio button 'selection' if no filter has been established from the Product field (by right click and 'Filter').

 The product reference must be specified

This message appears after having ticked the "Single" radio button if no product reference has been entered.

Cost already calculated by not updated.

This message appears after the entry of the year if a cost record corresponding to the selections exists in the provisional table. This is a non blocking warning.

Another calculation in process at this site

This message appears after the entry of the selection if a calculation is launched for several product or a product with descent of BOM and that another calculation is in process at the same site. This message is blocking because this type of calculation is exclusive for a given site.

Impossible to anticipate the revised cost : Accounting interface activated !

This message appears during control of the year field if this is greater than the current year and the ACCCSTIFA is set to Yes. A cost revision must be chronological to be able to be passed to accounting.
 

After the process, the log file can contain the following messages :

Error with BOM descent

A problem has occurred during the descent of the BOM (before the actual calculation). The process is interrupted, no update takes place.

Product-site record does not exist ...

This message appears if during the descent through the BOM a product-site record is not found.

No economic quantity for pro-rata distribution

This message appears if the Economic quantity and Technical lot fields for a parent product (product-site record fields) are found to be zero and that the Distribution setup for the fixed costs is set to 'Pro rata'. In this case the coefficient for the pro rata will be forced to 1.

This message can also concern a sub-contract product.

Product-cost record does not exist ...

This message appears if during the read of the component costs a product-cost record has not been found. The process continues but there will not be an update of the ITMCOST table.

No valid BOM link ...

This message appears if the read of the BOM for a parent product finds no valid link for the calculation date.

Routing record does not exist ...

This message appears if the routing (where the reference is the Routing-cost field from the product-site and the number of the selected alternative) does not exist for a parent product.

Routing not valid for the specified date

This message appears if the routing for the parent product is not valid for the calculation date.

No valuation section for this work center ...

This message appears if the Valuation section field for the work center is empty.

Transaction interrupted

This message appears during the write operation in the provisional table ITMCOSTW in the case of a serious problem. The process continues but there will not be an update of the ITMCOST table.

Error in the formulas for the Overheads OH code (formula code)

This message appears if the formula referenced in an Overhead column cannot be evaluated. The error is not blocking, the corresponding OH amount will be null.

Material record already present in the print file

This message appears during the preparation of the print line for a material if this material existed already in the temporary table serving the print.

The calculation result is remaining in the provisional table

This message appears after a blocking problem (write error or Product-cost non-existent) if an immediate update has been requested. There will not have been an update of the ITMCOST table and the calculation result will be in the ITMCOSTW table.

Existing record erased

This message appears if a standard or budget cost calculation is launched when this cost exists already.

The corresponding standard cost could not be created

This message appears if a revised or simulated cost calculation is launched when the corresponding standard cost did not exist and there has been a write problem for this standard cost (that is normally created automatically). It will then be necessary to manually create a standard cost to be able to view the other types of costs using "cost management" function.

Tables used

SEEREFERTTO Refer to documentation Implementation