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Manufacturing Order Cost Inquiry - Calculations
Manufacturing Order Cost Inquiry - Calculations
IA800E
A. Housekeeping
1. See the Common Processing Routines - Housekeeping section of this manual for a general discussion of this subroutine. Processing specific to this program is described below.
2. A parameter list is set up to receive the fast path parameters. A second parameter list is set up to pass the control parameters to the Manufacturing Order Cost Inquiry Report Print program (IA805E).
3. Key lists are defined for each file retrieved by the program.
4. Work fields are defined and program constants are initialized.
5. The Process Definition control record (MECTL1) is retrieved from the System Control file (CT100M) to retrieve the Rate Standard (RATEST). If this record is not found, a message is sent to the system operator, and processing is terminated.
6. The Design Engineering control record (DECTL1) is retrieved from the System Control file (CT100M) for version number checking.
7. The following information is retrieved from the Reference file (REFERP).
a. The applications installed record (category 012) is retrieved and the Shop Floor Installed Flag is saved to determine if the Shop Floor Control Application has been installed.
b. The date format record (category 049) is retrieved. If this record is not found, a message is sent to the system operator, the date format defaults to MMDDYY, and processing continues.
c. The user authorization (category 409) is retrieved.
d. The workstation assignment (category 428) is retrieved.
e. Order/receipt and inventory balance/movement quantity decimal positions are retrieved from the quantity field sizes record (category 446). If this record is not found, a message is sent to the system operator and the program terminates.
f. The system options record (category 133) is retrieved to determine whether this is a single- or multi-currency environment.
g. In a multi-currency environment, the company and location for this warehouse are retrieved from the Warehouse Description file (IC170M). The base currency for the company/location is then retrieved from the Reference File (category 002 - Entity Name).
8. If this program was entered via fast path from another screen, the passed data is validated and displayed on the function select screen.
B. Function Select
1. Initial validation is performed on the entered Select Screen fields.
a. Option 1 is valid only for a selected part. The Order Number field must be left blank.
b. Options 2, 3, 4 and 5 are valid only for a selected manufacturing order. The Part Number field must be left blank.
c. Any errors are highlighted, and an error message is displayed on the screen.
2. If option 1 is selected, the part number is validated against the Part Master file (DE100M). If it is not valid, the field is highlighted, and an error message is displayed on the screen.
3. If option 2, 3, 4 or 5 is selected, the order number is validated against the Manufacturing Order file (IC100ML1). If it is not valid, the field is highlighted, and an error message is displayed on the screen.
4. If option 4 or 5 is selected, the Shop Floor Installed Flag from the applications installed record (category 012) on the Reference file (REFERP) is checked. If the Shop Floor Control application is not installed, these options are invalid; the request field is highlighted and an error message is displayed on the screen.
5. A valid request calls the appropriate detail screen.
C. Detail
1. Part Select Screen (Option 1)
a. All manufacturing orders for the part number entered on the function select screen are retrieved from the Manufacturing Order file (IC100ML9). Those orders with an order status of O (open), C (closed) or Z (accounting closed) are displayed on the Part Select Screen. All other manufacturing orders are bypassed. If no manufacturing orders exist for the part number, an error message is displayed on the Part Select Screen.
b. The Part Select Screen allows the user to review the manufacturing summary costs for any of the displayed orders.
(1) The user may select an order for review by entering X before the desired order and pressing F6 - Order Summary. The Manufacturing Order Summary Costs Screen is displayed (see below for a discussion of the processing for this screen).
(2) No valid selections, more than one valid selection, or one or more invalid selections will cause the field in error to be highlighted and an error message displayed on the screen.
c. If the ENTER key is pressed, the function select screen is redisplayed and the previously selected part remains displayed.
2. Manufacturing Order Summary Screen (Option 2)
a. The Manufacturing Order file (IC100ML1) is retrieved for the selected manufacturing order. The start date, due date, close date, order status, order quantity and quantity received are retrieved and displayed on the screen.
b. For each manufacturing order, three cost factors are retrieved and the actual cost, cost of receipts and balance for each cost factor is calculated and displayed on the screen.
(1) For material cost, the actual cost is calculated as the sum of the quantity issued for each component, multiplied by the component's total standard cost. The cost of receipts is calculated as the manufacturing order quantity received multiplied by the parent part's material cost. The balance is the difference between the two costs.
(2) For labor cost, the actual cost is calculated as the sum of the direct labor hours reported for each operation, multiplied by the workcenter's standard labor rate. The cost of receipts is calculated as the manufacturing order quantity received multiplied by the parent part's labor cost. The balance is the difference between the two costs.
(3) For burden cost, the actual cost is a combination of two calculations:
(a) For labor-paced operations, the actual cost is calculated as the sum of the direct labor hours reported multiplied by the workcenter's standard burden rate.
(b) For machine-paced operations, the actual cost is calculated as the sum of the direct machine hours reported multiplied by the workcenter's standard burden rate.
(c) The actual cost for the entire order is the sum of these two calculations.
The cost of receipts is calculated as the manufacturing order quantity received multiplied by the parent part's burden cost. The balance is the difference between the actual cost and the cost of receipts.
(4) For miscellaneous cost, the miscellaneous cost rate and rate code are retrieved from the Miscellaneous Cost Header file (ME160M1) and the actual cost is calculated:
(a) For variable cost operations (rate code is L, M or O), the actual cost is calculated as the sum of the quantity completed, multiplied by the workcenter's miscellaneous cost.
(b) For fixed cost operations (rate code is X, Y or Z), the actual cost is the sum of the quantity completed, multiplied by the workcenter's miscellaneous cost divided by the part's average order quantity.
The cost of receipts is the manufacturing order quantity received multiplied by the parent part's miscellaneous cost. The balance is the difference between the actual cost and the cost of receipts.
c. The user may review any of the individual cost factors (material, labor and burden, or miscellaneous cost) by using a command key to display the appropriate screen (see below for discussions on the processing for each of these screens).
Note that if overflow occurred when calculating total costs, a warning message is printed on the report. This will indicate that amounts printed in the report might have been truncated due to overflow.
3. Material Costs Screen (Option 3)
a. The Manufacturing Order file (IC100ML1) is retrieved for the selected manufacturing order. The start date, due date, close date, order status, order quantity and quantity received are retrieved and displayed on the screen.
b. The actual issue quantity is retrieved from the Component Requirements file. The required issue quantity is calculated as the number of manufacturing order receipts multiplied by the component's quantity per divided by one minus the component scrap factor. The actual issue cost is computed as the quantity issued times the standard cost retrieved from the Part Master file (DE100M) for non-configuration costed parts, or from the Configuration Code file (EC140M) for configuration costed parts. The required issue cost is computed as the required quantity times the standard cost.
c. The user may review the order issue information for any component part displayed by entering an X before the desired part and pressing F8 - Issue Detail. The Issue Detail Screen is displayed (see below for a discussion of the processing for this screen).
d. The other command keys allow the user to review the Manufacturing Order Summary Screen (F6 - Order Summary) and the Receipt Detail Screen (F7 - Receipt Detail), or print the Manufacturing Order Detail Material Costs report (F16 - Print Material). If F16 - Print Material is pressed, the Manufacturing Order Detail Print program (IA805E) is executed.
e. If the ENTER key is pressed, the function select screen is displayed.
4. Receipt Detail Screen
a. Each manufacturing order receipt is retrieved from the Manufacturing Order Receipts and Components Issues Audit Trail file (IA800AL1) for the selected part and order number. The quantity received, post date and transaction date are displayed on the screen.
b. Cost information for non configuration costed parts is retrieved from the Part Master file (DE100M). Cost information for configuration costed parts is retrieved from the Configuration Code file (EC140M). The cost is multiplied by the quantity received to obtain the total cost.
c. If the user presses F11 - Material, the Material Costs Screen is displayed. If the user presses ENTER, the function select screen is displayed.
5. Issues Detail Screen
a. Each component issue for the selected component requirement is retrieved from the Manufacturing Order Receipts and Component Issues Audit Trail file (IA800AL2). The quantity issued, post date and transaction date are displayed on the screen.
b. Cost information for non configuration costed parts is retrieved from the Part Master file (DE100M). Cost information for configuration costed parts is retrieved from the Configuration Code file (EC140M). The cost is multiplied by the order quantity to obtain the total cost, which is displayed on the screen.
c. The user may request the Issues Detail report by pressing F17 - Print Issue Detail.
d. If the user presses F11 - Material, the Material Costs Screen is displayed. If the user presses ENTER, the function select screen is displayed.
6. Labor and Burden Costs Screen (Option 4)
a. Cost information for non configuration costed parts is retrieved from the Part Master file (DE100M). Cost information for configuration costed parts is retrieved from the Configuration Code file (EC140M).
b. The Labor Requirements file (IC125ML2) is retrieved to determine whether the part is machine- or labor-paced. All labor requirements for the selected order are retrieved and displayed on the screen.
c. The labor and burden cost fields are calculated as follows:
(1) If the piece rate is in pieces per hour, it is inverted to hours per piece. The labor cost is calculated as the labor rate times the calculated hours per piece.
(2) For a machine-paced operation, the labor hours per piece is calculated as the piece rate (machine hours per piece) times the number of persons per machine.
(3) For a crew operation, the labor hours per piece is calculated as the piece rate times the crew size (number of persons).
(4) For all other operations, the labor hours per piece is the piece rate.
(5) The same calculations are used to calculate the overhead (burden) cost, using the burden rate in place of the labor rate.
d. The user may review labor and burden detail for any of the displayed operations by entering X before the desired operation and pressing F5 - Labor & Burden Det. The Labor and Burden Costs Detail Screen is displayed (see below for a discussion of the processing for this screen).
e. The other command keys allow the user to review the Manufacturing Order Summary Screen (F6 - Order Summary) or print the Manufacturing Order Detail Labor and Burden Costs report (F18 - Print Lab & Bur). If F18 - Print Lab & Bur is pressed, the Manufacturing Order Detail Print program (IA805E) is executed.
f. If the ENTER key is pressed, the function select screen is displayed.
7. Labor and Burden Costs Detail Screen
a. Each labor step is retrieved from the Shop Floor Audit Trail file (IA800AL1) for the selected labor requirements. Cost information is retrieved from the Part Master file (DE100M) for non configuration costed parts and from the Configuration Code file (EC140M) for configuration costed parts. The transaction is checked for a reversal. The costs are multiplied by the order quantity after determining if the operation is machine- or labor-paced.
b. Command keys allow the user to return to the Labor and Burden Costs Screen (F12 - Labor & Burden) or print the Manufacturing Order Detail Labor and Burden Costs Detail report (F19 - Print Lab & Bur Det). If F19 - Print Lab & Bur Det is pressed, the Manufacturing Order Detail Print program (IA805E) is executed.
c. If the ENTER key is pressed, the function select screen is displayed.
8. Miscellaneous Costs Screen (Option 5)
a. Cost information is retrieved from the Miscellaneous Cost Header file (ME160M1) for non configuration costed parts or from the Configuration Code file (EC140M) for configuration costed parts. The costs are multiplied by the audit trail file order quantity.
b. Labor records are retrieved from the Labor Requirements file (IC125ML2) for the selected manufacturing order. The actual miscellaneous cost is displayed. The standard miscellaneous cost of receipts is calculated as the number of manufacturing order receipts multiplied by the miscellaneous cost for each operation.
c. The user may review miscellaneous cost detail for any of the displayed operations by entering X before the desired operation and pressing F5 - Misc Cost Detail. The Miscellaneous Costs Detail Screen is displayed (see below for a discussion of the processing for this screen).
d. The other command keys allow the user to return to the Manufacturing Order Summary Screen (F6 - Order Summary) or print the Manufacturing Order Detail Miscellaneous Costs report (F20 - Print Misc Cost). If F20 - Print Misc Cost is pressed, the Manufacturing Order Detail Print program (IA805E) is executed.
e. If the ENTER key is pressed, the select screen is displayed.
9. Miscellaneous Costs Detail Screen
a. Header data is retrieved from the Shop Floor Audit Trail file (IA800AL1) and the Labor Requirements file (IC125ML2).
b. The miscellaneous cost rate for each miscellaneous cost operation is calculated according to the rate code retrieved from the Miscellaneous Cost Header file (ME160M1).
c. All miscellaneous cost operations are retrieved from the Shop Floor Audit Trail (IA800AL1). Each transaction is checked whether it is a rework or complete operation. The reversal code is also checked.
(1) If the reversal code is blank, the quantity complete is negative.
(2) If the reversal code is not blank, the rework quantity is negative.
d. The miscellaneous total cost is computed as the quantity complete or rework quantity times the miscellaneous cost rate.
e. Command keys allow the user to return to the Miscellaneous Costs Screen (F13 - Misc Cost) or print the Manufacturing Order Detail Miscellaneous Costs Detail report (F15 - Print Misc Cost Det). If F15 - Print Misc Cost Det is pressed, the Manufacturing Order Detail Print program (IA805E) is executed.