PRODUCT COSTING

The OpenValue Product Costing module supports the decision-making process about manufacturing costs providing with all necessary costing figures.

The module is integrated in a seamless way with the OpenValue Shop Floor Control module and it enriches the OpenValue manufacturing execution solution with the product costing side.    

The costing figures, calculated in real time in different manufacturing execution phases, are as follows:

·       Standard Costs related to manufacturing master data structure, i.e. BoM and product master data; these are useful for engineering dpt as reference for design costs; the standard cost from product master data is reported also;

·       Planned Costs calculated from components and operation in production order before executing it (frozen at production order confirmation state) to provide a reference starting point to measure production dpt efficiency;

·       Actual Costs determined in real time during the manufacturing execution phase related to real components consumption and real workorders timing; variances costs are determined and posted at production order closure.   

 

Main features:

§  costing figures calculated in real time in performing the manufacturing order execution

§  accounting and analytic postings for WIP evaluation at workorder confirmation (hence, WIP account evaluated in real time and its value is detailed and provided at manufacturing order level)

§  two different cost rates for fixed and variable costs at WorkCentre level

§  actual direct costs posted in real time at workorder confirmation split in fixed and variable ones

§  delta analysis between planned costs and actual ones related to all costing figures at manufacturing order level

§  financial and analytic postings for the following variances

◦     full standard direct cost compared to full planned direct cost

◦     actual components consumption costs to the planned ones

◦     actual workorder times costs to the planned ones

•       Closure of manufacturing order for financial and analytic postings related to variances costs

•       Reporting (list, graph, pivot) for evaluating costing figures

 

Prerequisites:

§  stock evaluation as perpetual inventory for production materials (both components and semifineshed products)

§  WIP Account Set up at virtual production location level

 

 

Cost figures in Manufacturing Order

the following costing figures are calculated in real time and available in the single manufacturing order:

 

Production Unit Costs

Standard Costs

◦     Component Consumption Unit Costs - based on BOM explosion selected in manufacturing order evaluated at cost unit reported in the product master data

◦     Variable Direct Unit Costs - based on operations detailed in BoM selected in manufacturing order and evaluated at Variable Cost Rate in the responsible WorkCentre

◦     Fixed Direct Unit Costs - based on start and end times in the WorkCentre Responsible to the operation in BoM evaluated at Fixed Cost Rate

◦     ByProduct Amount - based on BoM explosion selected in manufacturing order and evaluated at cost unit reported in the product master data

◦     Full Direct Cost - based on the BoM, that’s the sum of its components detailed before (byproduct amount is also taken into account as minor cost)

◦     Current Standard Cost - reported from product master data

 

Planned Unit Costs: as described before for the Standard ones related to both the Components and Operations detailed in Manufacturing Order and frozen at its confirmation state.

 

Actual Unit Costs: as described before for the Standard and Planned ones taking into account for evaluation both the actual components and by-products quantities and the actual variable and fixed times entered in workorders confirmation; the actual produced quantity is to determine the unit costs from the overall amount.

 

 

Production Costs

Planned Costs: overall amounts of planned costs

 

Actual Costs: overall amounts of actual costs

 

Delta Costs: derived from comparing the actuals to the planned ones

 

WIP Amount: calculated in real time by summing all actual direct costs

 

 

Accounting and Analytic postings

at workorder confirmation:

·       all posted accounting amounts are based on actual times

·       analytic account for direct cost postings: in case this is empty in the manufacturing order, this is derived from the operation WorkCentre

·       accounting and analytic postings at workorder confirmation:

o   accounting posting with WIP account evaluated in real time at workorder declaration

o   analytic posting for collecting overall direct costs to be compared with budget amount at the end of the period for rates calculation

·       accounting date determined as the workorder actual end date

·       two financial accounts for variable and fixed direct costs

·       analytic account is taken from manufacturing order or derived from WorkCentre

·       cost figures updating in manufacturing order

 

at manufacturing Order Closure:

·       manufacturing order cost figures updating

·       accounting date determined as the actual scheduled end date

·       financial and analytic postings of variances

·       the WIP account balance is zero because of variances postings

 

 

Other Features

At manufactuting header level, we have:

•       button box for listing all accounting moves

•       button box for listing all analytic moves

 

 

the “compute price from bom” feature in the product master data has been changed to fit with new product costing calculation.

The “structure & cost” report at bom level has been enhanced for taken into account fixed direct costs also.

 

 

Product Costing Reporting

New “product costing” report is available also for collecting all financial figures and to check manufacturing orders not closed yet (financial closure not yet performed)