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Costing Sub-assemblies Sub-assembly manufacture costing - CostCalc 4.4 offers: 'As it happens' method or 'Traditional' costing method options Rapid calculation of total cost of sub-assemblies at three different selectable quantity levels: e.g., prototype and two production quantities, at output rates and labour or machine rates chosen by the user, with or without Work Efficiency (Eff%) factors and Learning Curve effects. Seven different Bill of Materials (BoM) blank pro-forma sheets with item count capacities ranging from 40 to 1000 items per sub-assembly. All BoM spreadsheets have Modification Record tables and sideways extensions to include data on three preferred suppliers per item. The ability to apply stage yields to each process and through a PYF* facility to identify realistic costs and order quantities for materials entered at different stages in the process sequence. This 'auto feedback to the BoM' feature includes progressive quantification of labour and material costs that arise directly from yield losses. A short-cut method for rapid cost estimating that avoids the need to compile a BoM, e.g., when the total cost of the BoM is already known or estimated. This is called ‘System Override’. The cost of each operation step: - with or without Work Efficiency, Process Yield effects and/or Learning Curve factors - the option to base the costing on labour rates or machine hourly operating costs or a mixture of both For inventory management, the cumulative value and proportion of total cost of manufacture step by step, enabling the value of Work in Progress to be seen easily at each process stage. For each operation step, times for all set-up, operation and rework activities are separately totalled as elements of the total labour and machine time. For each costed sub-assembly, its percentage utilisation of process equipment or headcount at each Workstation, with overload warnings where stated production capacity is exceeded. Additionally, there is a facility for monitoring common capacity utilisation across a whole project. For manual process steps, the number of operators (or percentage of one operator's time) needed to give the output rate specified by the user can be determined, also with overload warnings. Determination of the number of operator-hours required to set up, assemble, rework, inspect and test the (daily) output batch. Set-up costs can be treated separately from operation costs, but this is optional. For each sub-assembly, the ability to set: - three different cost level options for first time set-up activities - a further three for routine batch/shift set-up - and yet a further three for each of the process and rework operation activities. For each one of the 30 optional process groups there is the ability to call up several different machines working in parallel and/or up to three workstations operating in series, making a maximum total of 90 individual processes if required. Each workstation may contain an infinite number of machines and/or operators. The target number of shifts and weeks to complete an order. The relevant spreadsheets give a choice of three methods. Each sheet produces results for prescribed (target) headcount based on machine operations, on standard operation times, or with limited headcount defined by the user. Likely total production headcount requirements to meet specified output rates, optionally derived in three different ways. The option to choose the main costing currency and a second one and then instantly compare costs in the two different decimal currencies selected. Pie charts showing percentages for key cost data: Labour/Machines/Materials and also Operations/Rework/Set-up costs. Modification procedure that automatically records the cost effects of each change on all affected parameters, with cumulative data enabling monitoring of cost-reduction progress over time. NOTE: Although treated as being at a lower level in the structural hierarchy of the 'materials sub-assembly product' pyramid, in fact any sub-assembly file kit can also be used to accurately cost a product. * PYF: Progressive Yield Facility - auto-correction of BoM quantity and cost data by feedback of process yield information. |
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