Work Order Plus Advanced Feature Manual 3

Reset Order Transaction Data

Application Overview

The Reset Order Transaction Data utility restores order statistics at the transaction level if a data integrity issue were to occur.  This will recover order data, like reported quantity, labor hours, production cost, etc. from transactions not posted. 

Run Instructions

Main Menu è  Util_Setup è Global Setup è Utilities è Reset Order Transaction Data

 

(Figure 10) Reset Order Transaction Data Selection Screen

Entry Field Descriptions

 

Name

Type and Description

1. Starting Order No

6 numeric digits.

Enter the starting order number for a range of work orders to reset. 

Defaults to All.

2. Ending Order No

6 numeric digits 

Enter the ending order number for a range of work orders to reset.

Defaults to the starting order number.

3. Update?

Y or N.

Enter Y if you want to reset all data.

Defaults to N.

(Figure 11) Reset Order Transaction Data Selection Screen

 



(Figure 12) Reset Order Transaction Data Report

 

 

Chapter 2: Cost Master

The Cost Master enables the Standard Product Costing feature in Macola's Manufacturing Module for Work Order Plus.  This allows you to create a separate environment to build cost from bill of material and routing, inspect, fine tune, and eventually roll-up to the Standard Cost in the Item master.  Our implementation adopts most of the original concepts from Macola's Standard Product Costing, but enhances the user interface and selection criteria.  In addition, Cost Master provides audit tools so the detail of each standard cost update can be reviewed in the future. 

 

Each cost master record stores the cost of one item.  If the item is a purchased item, the cost could be the last purchase cost.  If the item is a manufactured item, the cost of the parent item would include costs from all components and subcomponents, as well as the costs from production and subassemblies.  The components of a parent item are defined in Bill of Material while the manufacturing process is defined in Standard Routing.  For instance, parent item P is made from components C1, C2 and C3.  C3 is made from components C31 and C32.  C1, C2, C31 and C32 are purchased items. 

                         P

                         

               ┌─────────┼─────────┐

                                 

              (1)       (1)       (1)

              C1        C2        C3

                                   

                              ┌────────┐

                                       

                             (1)       (1)

                             C31       C32

 

The cost structure of each item is as follows:

 

 

C31

C32

C3

C1

C2

P

Material V/A

15

15

0

10

20

0

Material Total

15

15

30

10

20

60

Production V/A

0

0

40

0

0

50

Production Total

0

0

40

0

0

90

Total Unit Cost

15

15

70

10

20

150

 

The above table shows how cost for each item is stored and calculated.  Each column represents the data of one cost master record.  The last row shows the total unit cost of each item.  Parent item P, for example, costs $150 where $60 is from material and $90 is from production.  Material cost of parent item P includes the cost from every component and subcomponent.  Likewise, the production cost contains the cost from producing the item and all subassemblies.  The $90 production cost is from both the assembly of the parent item P, which costs $50, and the assembly of component C3, which costs $40.  

 

You can find two types of cost in the chart above, Value Added and Total.  Value Added refers to extra features of an item (product, service, etc.) that go beyond the standard expectations while adding little or no cost.  Total cost is the sum of the value added and cost from all the subcomponents.  To illustrate, the assembly of C3 costs $40 so the value added is $40.  The total material cost of $30 is from the material value added of C31 and C32. 

 

Inspecting and calculating item costs can be extremely complicated and time consuming.  Plus, the cost can be incorrect if not calculated in the right sequence, which is from the bottom of the production structure to the top.  This solution provides a separate environment to calculate cost so any change will not affect the item cost.  In addition, it offers tools to help you process multiple items at once and provides the screens and reports needed for inspection and evaluation.  In the following sections you will learn the purpose and instructions of each program. 

 

The following is a simple outline of the chapter:

  • Processing      – Provides all the applications to update cost masters in batch.
  • Maintenance – Screen applications to review or edit single or plural cost master records.
  • Inquiry           – Inquiry applications to review cost master audit history.
  • Report                        – All reports to inspect and evaluate cost master.

Processing

The Processing menu provides all the utilities to create build-up cost in batch and update standard cost.  There are four steps to build up standard cost:

  • Create cost master record for each item, either manually or through Create Cost Master from Item File.
  • Update unit cost of all purchased items through Roll Last Cost to Current Value-Add Material Cost.
  • Build up cost from routing through Recalculate Current Value-Add Cost from Routing.
  • Rollup bill of material cost from lower levels through Current Total Cost Build-up.

 

Use “Current to Standard Roll” to update standard cost in the item master.  You can use “Create Cost Master from Item File” to create cost master records if you have never used this feature before.

Roll Last Cost to Current Value-Add Material Cost

Application Overview

This feature is used to update the latest unit cost for all selected cost master of purchased items.  You can select a range of cost master to update by item number, product category, buyer/analyst code and material cost type.  You can choose to update the latest unit cost from last cost, average cost or standard cost, or you can use the last purchase cost or price code if they are available.

 

(Figure 13) Roll Last Cost to Current V/A Material Cost Selection Screen

Entry Descriptions

 

Name

Type and Description

Starting Item No

15 alphanumeric characters.

Enter the starting item number for a range of cost masters to update.  Press the F7 Keyto search for an item by item number or press the F8 Key to search for an item by item description.

Defaults to All.

Ending Item No

15 alphanumeric characters.

Enter the ending item number for a range of cost masters to update.  Press the F7 Keyto search for an item by item number or press the F8 Key to search for an item by item description.

Defaults to the starting item number.

Starting Product Cat

3 alphanumeric characters.

Enter the starting product category for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no product category only.

Defaults to All.

Ending Product Cat

3 alphanumeric characters.

Enter the ending product category for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no product category only.

Defaults to the starting product category.

Buyer Code

2 alphanumeric characters.

Enter the buyer/analyst code for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no buyer code only.

Defaults to All.

Material Cost Type

2 alphanumeric characters.

Enter the material cost type for a range of cost masters to update.  Press the F7 Key to search for an existing material cost type.  Press the F1 Key to select items that have no material cost type only.

Defaults to All.

Use Which Cost?

1 alphanumeric character.

Valid entries are:

R      - Last cost

S      - Standard cost

A      - Average cost

Enter the type of unit cost to roll to the cost master.

Defaults to R.

Override If Last Purchase Cost Exists?

Y or N.

Enter Y to use Last Purchase Cost as the unit cost.  If it is available, it will override last/standard/average cost.

Defaults to Y.

Override If Price Table Exist

Y or N.

Enter Y to use the Price Code Table to obtain the unit cost.  The program uses Order Minimum, Economic Order Quantity and Order Multiple to determine the price level and selects the minimum price as the unit cost.  If it is available, it will override last/standard/average/last purchase cost.

Defaults to Y.

Roll If Mtrl Cost Field Is Fixed?

Y or N.

Enter Y if you want to update cost masters where the material cost is fixed.

Defaults to N.

 

(Figure 14) Roll Last Cost to Current V/A Material Cost Selection Screen


Recalculate Current Value-Add Cost from Routing

Application Overview

This program calculates the routing cost for manufactured items and updates labor, overhead and other costs to the cost master.  Selected items should have a default routing since the calculation is based on it.

 

(Figure 15) Recalculate Current V/A Cost from Routing Selection Screen

Entry Descriptions

 

Name

Type and Description

Starting Item No

15 alphanumeric characters.

Enter the starting item number for a range of cost masters to update.  Press the F7 Keyto search for an item by item number or press the F8 Key to search for an item by item description.

Defaults to All.

Ending Item No

15 alphanumeric characters.

Enter the ending item number for a range of cost masters to update.  Press the F7 Keyto search for an item by item number or press the F8 Key to search for an item by item description.

Defaults to the starting item number.

Starting Product Cat

3 alphanumeric characters.

Enter the starting product category for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no product category only.

Defaults to All.

Ending Product Cat

3 alphanumeric characters.

Enter the ending product category for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no product category only.

Defaults to the starting product category.

Buyer Code

2 alphanumeric characters.

Enter the buyer/analyst code for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no buyer code only.

Defaults to All.

Material Cost Type

2 alphanumeric characters.

Enter the material cost type for a range of cost masters to update.  Press the F7 Key to search for an existing material cost type.  Press the F1 Key to select items that have no material cost type only.

Defaults to All.

Recalculate Fixed Cost Fields?

Y or N.

Enter Y to update cost masters for which the cost is fixed.

Defaults to N.

 

(Figure 16) Recalculate Current V/A Cost from Routing Selection Screen

 


Current Total Cost Build-up

Application Overview

This application will accumulate the new current total cost for selected manufactured items through the bill of material.  It accumulates the material, labor, and overhead cost from each component to build up the total cost of the parent item.  The program processes the cost master of the lowest level components first.  As a result, the component cost will be built up before that of the parent items.  This is the last step for cost calculation, so make sure you have completed editing the current value added cost.

 

(Figure 17) Current Total Cost Buildup Selection Screen

Entry Descriptions

 

Name

Type and Description

Starting Item No

15 alphanumeric characters.

Enter the starting item number for a range of cost masters to update.  Press the F7 Keyto search for an item by item number or press the F8 Key to search for an item by item description.

Defaults to All.

Ending Item No

15 alphanumeric characters.

Enter the ending item number for a range of cost masters to update.  Press the F7 Keyto search for an item by item number or press the F8 Key to search for an item by item description.

Defaults to the starting item number.

Starting Product Cat

3 alphanumeric characters.

Enter the starting product category for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no product category only.

Defaults to All.

Ending Product Cat

3 alphanumeric characters.

Enter the ending product category for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no product category only.

Defaults to the starting product category.

Buyer Code

2 alphanumeric characters.

Enter the buyer/analyst code for a range of cost masters to update.  Press the F7 Key to search for an existing product category.  Press the F1 Key to select items that have no buyer code only.

Defaults to All.

Material Cost Type

2 alphanumeric characters.

Enter the material cost type for a range of cost masters to update.  Press the F7 Key to search for an existing material cost type.  Press the F1 Key to select items that have no material cost type only.

Defaults to All.

Reset Low Level Code First?

Y or N.

Enter Y reset low level codes of all items before cost build-up.  This will make sure the update sequence is correctly from components to parent items, but may take a while depending on your inventory size.

Defaults to Y.

Process Item Only w/ Last Change Date On or Prior to

A date in the standard date format (MM/DD/YY).

The application only builds up cost for items that have been changed on or before this date.

Defaults to the system date.

Include Scrap?

Y or N.

Enter Y to include the scrap factor in the cost build-up.  It will increase the unit cost of selected items.

Defaults to N.

 

(Figure 18) Current Total Cost Buildup Selection Screen


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