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The Cost
Module is responsible for estimating and tracking the costs
associated with the manufacturing process. The key features are as
follows:
Both
fixed overhead and variable overhead methods and a wide range of cost
drivers that can be applied job-by-job, step-by-step to work in process
are supported.
Overhead
methods included as standard:
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Percentage
of direct labor costs.
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Rate
per man hour of direct labor.
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Rate
per machine hour.
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Rate
per unit of production.
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Percentage
of direct material cost.
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Rate
per unit of direct material.
Manual
and custom overhead methods may be used.
Separate
fixed and variable overhead methods may be assigned.
Overhead
methods may be established by product class.
A
labor grade file maintains individual employee numbers and their rate
per hour.
Each
labor grade uses a $STANDARD employee which is the average rate for the
labor grade and is used to prepare quotes or for projected costs.
An
employee may be entered for each labor grade for which they qualify.
This allows different rates per hour to be used according to the work an
employee is performing.
Each
operation step on a Master Route can have a labor grade assigned
independently for setup and for cycle time. In this manner, WorkShop can
distinguish the cost of setup separately from the cost of production.
Cycle
time has a percent field which allows WorkShop to account for an
operator running more than one work center at a time.
The
Planned Cost process provides a way of calculating the cost of an
item manufactured in various quantities across different routes.
Common
uses of the Planned Cost process include
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Establishing
economical lot sizing
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Determining
optimum routes to manufacture an item.
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Establishing
a way to validate an inventory standard cost using the current
routes.
The
Planned Cost function projects the material, labor and overhead
costs of manufacturing an item in a specified quantity using a
designated master route.
The
Work Order Cost function provides a snapshot of job costs and
allows a comparison of those costs to saved/quoted costs.
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The
Work Order Cost screen displays
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The
WIP costs of completed steps.
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The
projected costs to finish the job.
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The
total costs for the job.
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A
breakdown of how the costs are distributed.
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The
cost per unit or for the total job.
The
current work order costs are automatically calculated each time the
screen is displayed.
A
Work In Process report permits up to the minute reporting on the
value of WIP.
WIP
can be broken down by material, labor and overhead and by the type of
order:
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Assemble
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Build
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Maintenance
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Rework
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Work
Order
The
detail of the WIP reporting can include showing costs by route step.
A
Variance Analysis report allows you to compare a job’s cost
performance to its quoted costs.
The
variance reporting can be done on in process or completed work orders.
The
variance reporting can be done for material, labor and overhead costs
right down to the route steps.
An
Average Cost report will calculate the average material, labor
and overhead costs for an item over a specified period of time.
As
part of the process of finding average costs for an item, parameters may
be set that will exempt costs that are below a certain amount or above a
certain amount. This allows out of the ordinary costs to be excluded
from the average cost calculations.
The
ability to find average costs has several important advantages:
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Since
the costs can be calculated down to the operation route step, there
is a tool to analyze the effectiveness of the manufacturing
procedures.
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Trends
over time can be developed.
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The
average cost information can be used to set prices when negotiating
with a customer.
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The
information can also be used to determine cost standards.
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