Budgeted cost calculation
Use this function to calculate the budgeted cost of one or a range of products at a specified site.
This function is typically used to prepare provisional costs for the following year. Costs are calculated from a set of user-defined parameters. These include defining a specific route or bill of material (BOM) alternative from which to base the new costs, and applicable quantities.
A single product-site record has only one budget cost. You can prepare simulated costs then update the product-costs records when the costs are finalized.
Costs are established from routing data (time) and valuation dimension data for work centers associated with a route on a specified calculation date.
The cost calculation can optionally descend through a 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. Alternatively, the calculation can be performed at the first level of a BOM, from the standard costs of the components of the calculated products. If a calculation has been run previously and costs approved, the latter type of calculation is adequate, that is, for the first level only.
This function requires exclusive access to the products-site records. Subsequent calculations can only be run when the current calculation run has been completed.
By definition, a 'material' does not have to be a 'component' in a BOM. A Material cost selection field determines how material costs are calculated.
Subcontract costs are calculated from the reference price defined for an operation in a route. The valuation method, if defined on the products-sites record, is considered. Price lists are also considered. The cost of subcontract materials is from a price list; if the price list is not found, the standard cost can be used if the PURPRICE - Price by default standard cost parameter (ACH chapter, PRI group) is set to 'Yes'.
Prerequisites
Refer to documentation Implementation
Screen management
The Budgeted cost calculation function is made up of a single screen into which you define the products to be included in the calculation run and specify your run time calculation parameters.
Entry screen
Define the site for which budgeted costs are required, then use the Product section to filter or select the products to be included in the calculation run:
- Product. This field is only required if you click (select) the Unique radio button.
- Formula. This field is only required if you click the Selection radio button. You can use a filter calculation expression formula to select the products to be included in the calculation run or apply a filter. Click Formula wizard from the Actions icon to enter, select or build a filter calculation expression using the formula editor; to apply a filter, click Filter from the Actions icon. Click the Selection action to confirm.
- Calculation quantity. 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. You can change the default quantity.
Use the Validity section to specify your run time parameters:
- Fiscal year. A calculation run for a combination of 'Site' + 'Product' + 'Fiscal year' that has been run previously overwrites the previous calculation if the selected type of update is 'Deferred' or 'Immediate' (field Update (field MAJ)).
- Routing code. If you leave this field blank only material costs are calculated.
- BOM code. The default BOM alternative displayed is the first BOM alternative associated with the selected routing alternative (field Routing code (field ROUALT)). The default alternative BOM code can be changed.
- Calculate all BOM levels. This check box is only available if this calculation run is for a single product (the Unique radio button is selected). If selected, the cost calculation process will descend 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 calculation process stores the budget cost for each parent product found. If left 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.
- Fixed costs distribution. The fixed overhead costs (material loss, setup rate, operation loss rate, fixed rate) can be distributed as a total sum or spread pro rata from the combination of the calculation quantity/economic lot quantity.
- Material cost. Used for the calculation of material costs. The default cost type is defined in the CLCBUDMAT-Mat cost selection bud calc parameter (TC chapter, COS group). You can change the default cost type.
- Dimension rate. Used for the calculation of labor and machines. The default cost type is defined in the CLCBUDRAT-Dimension rate selection bud C parameter (GPA chapter, COS group). You can change the default dimension rate.
- Overhead column. Used for the calcuation of overheads. The value of an overhead is calculated by applying the fixed rate or the formula in the chosen calculation column. The default column is defined in the OVECOLBUD-Budget calc overhead column parameter (GPA chapter, COS group). You can change the default column.
Having defined your run time parameters you must then decide whether to run the calculations as a simulation or to update the products-costs records. If updating the products-costs records, you can choose to update immediately or you can defer the update. You can print the results of the run from this function. A log file detailing the results of the run is also produced. The end of run reports are in summary if the Calculate all BOM levels (field DESCEND) check box is left clear (not selected).
Block number 1
Storage site (field STOFCY) |
Use this field to define the storage site (warehouse). The site defined on the user record is displayed by default but can be amended.
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Product
field TOUS |
Use this radio button to select records to be updated.
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Block number 3
Product (field ITMREF) |
Use this field to specify the product code to be updated. |
Formula (field FILART) |
Enter, select or build an Enterprise Management filter calculation expression using the formula editor.
This field is only available if the Selection |
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. |
field STU2 |
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 5
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 |
BOM type (field BOMALTTYP) |
Select Manufacturing if you manufacture this bill of materials (BOM); if it is procured from a subcontractor, select Subcontracting. |
Routing code (field ROUALT) |
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). |
BOM code (field BOMALT) |
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.
By definition, a material does not have to be a component. The selection field is used to determine how its cost is calculated when defined as 'Calculated' and not 'Entered'. |
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.
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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:
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
Update (field MAJ) |
Use this field to control any postings to the products-costs records.
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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). |
Reports
By default, the following reports are associated with this function :
ITMCOST : Detail cost calculations
NA-ITMCOST : Single Level BOM Report
This can be changed using a different setup.
Batch task
This function can be run in batch mode. The standard task CALCSTBUD is provided for that purpose.
Error messages
In addition to the generic error messages, the following messages can appear during the entry :
Site... Record non-existentThis message is displayed if the entered site code is invalid. You can check this using the selection window.
The product reference must be specifiedThis message is displayed if the Unique radio button is selected and the Product field (field ITMREF) is blank.
Product-site record does not exist ...This message is displayed if the entered product does not exist at the defined site. You can check this using the selection window.
Code not valid for this site!This message is displayed if the entered 'alternative' (routing/BOM) is valid for a different site.
No BOM alternative is valid for the selected siteThis message is displayed if none of the 3 associated BOM alternatives is valid for the defined site.
No BOM alternative foundThis message is displayed if no BOM exists in the 3 alternatives associated with the routing alternative for the defined product.
No routing alternative : Warning material calculation only !This message is displayed if the routing alternative is set to 0 (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 is displayed if the Selection radio button is selected and no filter has been defined.
To apply a filter, click Filter from the Actions icon in the Product field (field ITMREF). Click the Selection action to confirm.
Calculation prohibited: the Entered/calculated code is 'entered'This message is displayed if for the entered product at the defined site, the 'Entry/calculated' code corresponding to the function being processed is set to 'Entered'. This means that the data can not be overwritten by a calculation run.
The cost exists already, it will be erased on the calculation updateor
If one of the costs corresponding to these selections exists already, it will be erased on the update of the calculation.This message is displayed for a standard or budget type calculation if the cost already exists for a product-site reference or for the year. This is a non-blocking warning.
Cost already calculated but not updated.This message is displayed if a cost record corresponding to the Fiscal year selections exists in the provisional table. This is a non-blocking warning.
Another calculation in process at this siteThis function requires exclusive access to the products-sites records. This message is displayed if a calculation is in process at the same site. This is a blocking message.
Impossible to anticipate the revised cost : Accounting interface activated !This message is displayed if the defined Fiscal year is later than the current year and ACCCSTIFA is set to 'Yes'. A cost revision must be chronological to be able to be passed to accounting.
The log file can contain the following messages resulting from the calculation run:
A problem occurred whilst descending through the bill of materials (BOM) to the lowest level (before the actual calculation). The process was interrupted, no update has taken place.
No economic quantity for pro-rata distributionThis message is displayed if 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 for a parent product are 0 (zero) and the Fixed costs distribution (field FXDCSTDSP) is set to 'Prorata'. In this case the pro rata coefficient will be 1.
This message can also apply to a subcontract product.
Product-site record does not exist ...This message is displayed if a product-site record is not found whilst descending through the BOM.
Product-cost record does not exist ...This message is displayed if a product-cost record for a component is invalid. The process continues but the ITMCOST table will not be updated.
No valid BOM link ...This message is displayed 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 is displayed 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 dateThis message is displayed if the routing for the parent product is not valid for the calculation date.
No valuation section for this work center ...This message is displayed if the Valuation section field for the work center is empty.
Transaction interruptedThis message is displayed if a serious error occurs during the write operation to the ITMCOSTW provisional table. The process continues but the ITMCOST table will not be updated.
Error in the formulas for the Overheads OH code (formula code)This message is displayed if the formula referenced in an Overhead column cannot be evaluated. The error is not blocking, the corresponding Overhead amount will be null.
Material record already present in the print fileThis message is displayed during the preparation of the print line for a material if the material already exists in the temporary table serving the print.
The calculation result is remaining in the provisional tableThis message is displayed after a blocking problem (write error or Product-cost non-existent) if an immediate update has been requested. The ITMCOST table will not have been updated; the calculation result will be in the ITMCOSTW table.
Existing record erasedThis message is displayed if a standard or budget cost calculation is launched when the cost already exists.
The corresponding standard cost could not be createdThis 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 a 'cost management' function.