CostCalc 4.4

Cost Estimating

By allowing the user to accept, ignore or add to the list of assembly processes covered, CostCalc 4.4 can be applied as a rapid 'first shot' estimator or a sophisticated and detailed analytical tool with 'what if' facilities. In this application it is intended for a wide range of manufacturing situations and operates concurrently in any two decimal currencies with the ability to switch instantly between them. The system also has intrinsic value as a professional training tool for all disciplines associated with production, including accounting and design staff.

For both manual and mechanized process operations, the data required for costing are similar to those needed to calculate the proportion of manufacturing capability occupied by the product being assessed. For this reason the ‘result’ spreadsheets for Sub-assembly incorporate details of the production capacity utilisation factor for each process. Visual warnings appear if available capacity is inadvertently exceeded. A further point is that the same types of data are used to estimate approximate headcount requirements.

The system provides high visibility of all parameters and gives the option of covering up to 90 different processes in sequence. For these reasons it may appear complex at first sight, but depending on the project objective and time available for estimating, it can be applied in an abbreviated form by entering data only for a few key processes and ignoring the rest. It can even be used for 'scarce resource' cost-estimating methods, for example, basing the cost solely on occupancy times for one critical machine. For most processes, the user is given the choice between entering data enabling estimates for quotation purposes, or entering actual process time measurements derived from work study. 

Versions are available for 30, 60 or 90 different processes in sequence. The Operating Manual is printed in book form as well as being on CD in pdf format. Blank pro-forma spreadsheet kits and a set of completed examples are available on the same CD. Much of the guidance is also available on pop-up Help pages that are distributed among the various project files and comments for individual cells.

To simplify its application, users are asked to complete on-screen questionnaires for the three main spreadsheets concerning Materials, Sub-assembly manufacture and Product manufacture respectively. From these inputs, costs and other management data are calculated and summarized on the related ‘Results’ spreadsheets.