SytelineMaster

ITEM MAINTENANCE WINDOW – GENERAL TAB

 

Cost Type: item.cost

Cost Method: item.cost-method

(Standard) Unit Cost: item.unit-cost

Current Unit Cost: item.cur-u-cost

Notes:

• The Cost Type can be either Actual or Standard with the stored value being "A" or "S".

• The Cost Method and the associated field values can be (L)IFO, (F)IFO, (A)verage, (S)pecific, (C)Standard.

• The label and usage of the Unit Cost field varies depending on the item’s Cost Type and Method. If the item is standard-costed, the label "Standard Unit Cost". Otherwise, it is just "Unit Cost". Usage of the field is the following:

1. Standard cost if the item’s Cost Type is Standard

2. Average cost if the item is Actual/Average

3. Cost at the top of the stack (next issue cost) if Actual/FIFO

4. Cost at the bottom of the stack if Actual/LIFO

5. Last receipt cost if Actual/Specific

6. This field is primarily informational if Actual with LIFO, FIFO or Specific as the actual cost data used when for the item is stored in the LIFO/FIFO stacks or the item’s locations (or lots) if the item is Specific.

• The Current Unit Cost is used as follows:

  1. For purchased items: Holds the Purchased Current Unit Cost fields from the Cost Maintenance screen. That can be manually entered and may be updated by PO receiving (depending on how the Update Current Cost PO parameter is set).

  2. For manufactured items: Holds the Manufactured Current Unit Cost from the Cost Maintenance screen. That is the unit cost for the item as calculated based on it’s current routing and BOM. Updated when you run the BOM Cost Rollup or do maintenance to the item’s current routing/BOM.

ITEM MASTER COST MAINTENANCE WINDOW – COST DETAIL TAB

Assembly column:

Setup: item.asm-setup

Run: item.asm-run

Material: item.asm-matl

Tool: item.asm-tool

Fixture: item.asm-fixture

Other: item.asm-other

Fixed: item.asm-fixed

Variable: item.asm-var

Outside: item.asm-outside

Accumulated column:

Setup: item.comp-setup

Run: item.comp-run

Material: item.comp-matl

Tool: item.comp-tool

Fixture: item.comp-fixture

Other: item.comp-other

Fixed: item.comp-fixed

Variable: item.comp-var

Outside: item.comp-outside

Unit Costs area:

Current Unit Cost: item.cur-u-cost (same as on I/M general screen)

(Standard) Unit Cost: item.unit-cost (same as on I/M general screen)

Cost Totals area:

Subtotal: Calculated as the sum of the assembly column

Material Subtotal: item.sub-matl

Assembly Total: Calculated as Subtotal plus Material Subtotal

Accumulated Total: Calculated as the total of the Accumulated column

Notes:

• The ASSEMBLY column is the cost of the item’s current operations and of purchased materials in its current BOM.

• The ACCUMULATED columns is the ASSEMBLY values plus the cost of any manufactured items which exists in the item’s current BOM.

• The BOM Cost Rollup rolls costs from the bottom of your indented BOMs up and populates these columns.

• They are updated on-the-fly when you make manual changes to the item’s current routing and BOM. Those updates just reflect the changes you are making. If lower level items’ costs change, you must run the BOM Cost Rollup to have those changes rolled up into parent items.

• The ECN posting process does not change these costs on-the-fly. Those changes are not reflected until the BOM Cost Rollup is run.

• For purchased items, the cost being rolled from that item up into its parent items is also put into the Material row of both columns of this screen when you run the BOM Cost Rollup. That will be the item’s Purchased Current Unit Cost if it is an actual-costed item or if it is standard-costed and you answer No to the "Use Std Cost for Purchased Items" option. It will be the item’s standard cost if you answer Yes to that option.

ITEM MASTER COST MAINTENANCE WINDOW – COST MAINTENANCE TAB

Unit Cost area:

Material Cost: item.matl-cost

Material: item.unit-mat-cost

Freight: item.unit-freight-cost

Duty: item.unit-duty-cost

Brokerage: item.unit-brokerage-cost

Labor Cost: item.lbr-cost

Fix Ovhd Cost: item.fovhd-cost

Var Ovhd Cost: item.vovhd-cost

Outside Cost: item.out-cost

Total Unit Cost: item.unit-cost (same as on I/M General screen)

Manufactured Current Unit Cost area:

Cur Material Cost: item.cur-matl-cost

Cur Labor Cost: item.cur-lbr-cost

Cur Fix Ovhd Cost: item.cur-fovhd-cost

Cur Var Ovhd Cost: item.cur-vovhd-cost

Cur Outside Cost: item.cur-out-cost

Cur Unit Cost: Calculated as sum of the above fields

Purchased Current Unit Cost area:

Material: cur-mat-cost

Freight: cur-freight-cost

Duty: cur-duty-cost

Brokerage: cur-brokerage-cost

Cur Unit Cost: Calculated as sum of the above fields

Notes:

• The unit-*-cost fields under Material Cost will only be filled if the item is purchased with Cost Type of Standard.

• The item’s Current Unit Cost on the general screen (item.cur-u-cost) will hold either the sum of the Purchased Current Unit Cost fields if the item has a Source of Purchased or Transferred, or the Manufactured Current Unit Cost fields if the Source is Manufactured.

• The Purchased Current Unit Cost is updated when you process a PO receipt if the "Update Current Cost" PO parameter is set to Last or Average.

• The Manufactured Current Unit Cost is populated by the BOM Cost Rollup utility and is updated on-the-fly when you make manual changes to the item’s current routing or BOM.

• For Standard-costed items, the Unit Cost can only be manually changed if the item has zero on hand and has no transactions in the material transaction table. Otherwise, it can only be changed by running the Roll Current Cost to Std Cost utility.

• For Actual-costed items, the Unit Cost can only be updated if it has a Cost Method of Average since that is where the item’s average cost is stored. If the item is LIFO, FIFO or Specific costed, the item’s cost data is stored in other tables and this field can not be updated since it is informational only.

ITEM MASTER COST MAINTENANCE WINDOW – COMPARE TAB

Current column:

The "item.comp-" fields listed above as being on the Cost Detail tab are displayed in the Current column of this screen. The Total is calculated by the program.

Standard column:

Setup: frzcost.comp-setup

Run: frzcost.comp-run

Material: frzcost.comp-matl

Tool: frzcost.comp-tool

Fixture: frzcost.comp-fixture

Other: frzcost.comp-other

Fixed: frzcost.comp-fixed

Variable: frzcost.comp-var

Outside: frzcost.comp-outside

Total: Calculated by the program

Unit Costs area:

Current Unit Cost: item.cur-u-cost (same as on I/M general screen)

(Standard) Unit Cost: item.unit-cost (same as on I/M general screen)

Effective Dates:

Current: job.rollup-date

Standard: frzcost.freeze-date

Notes:

• An frzcost record is created when you run the Roll Current Cost to Std Cost utility for an item.

• The rollup-date is from the item’s current job and is the last time the BOM Cost Rollup processed the item. When you first add a current operation for an item, the system creates a behind-the-scenes job record to which to link the item’s current routing and BOM. That rollup-date is updated each time the BOM Cost Rollup is run.

• The freeze-date is from the frzcost record and is the last time the Roll Current Cost to Std Cost utility was run for the item.

ITEM MASTER COST MAINTENANCE WINDOW – STD COST TAB

Assembly column:

The fields shown are all of the fields that begin "asm-" found in the frzcost table.

Accumulated column:

The fields shown are all of the fields that begin "comp-" found in the frzcost table.

Unit Costs area:

Current Unit Cost: item.cur-u-cost (same as on I/M general screen)

(Standard) Unit Cost: item.unit-cost (same as on I/M general screen)

Effective Dates:

Current: job.rollup-date

Standard: frzcost.freeze-date

Cost Totals area:

Subtotal: Calculated as sum of the frzcost.asm-* fields

Material Subtotal: frzcost.sum-matl

Assembly Total: Calculated as sum of Assembly column plus the Material Subtotal

Accumulated Total: Calculated as sum of Accumulated column

Notes:

• The rollup-date which is from the item’s standard job. When you run the Roll Current Cost to Std Cost utility, the system creates a standard job. The rollup-date in the standard job is set to the rollup date in the current job and represents the last time the BOM Cost Rollup utility processed the item before Roll Current Cost to Std Cost was run.

Overview

There are four lead time fields in the Syteline item master: fixed, variable, paperwork and dock-to-stock. The fixed, paperwork and dock-to-stock leads are expressed in days and the variable is expressed in hours (run time per piece). For purchased items, they must be manually entered. For manufactured, they can be either manually entered or you can use the Lead Time Processor utility which populates the fixed and variable fields using the times in the item’s current routing .
In general, purchased and transferred items will have a fixed lead time and perhaps a paperwork and dock-to-stock but no variable. Manufactured items will typically have a fixed, variable and perhaps a paperwork but not a dock-to-stock. The following is an explanation of what functions in the system use lead times and how they are used. It is broken down by manufactured vs purchased items.
NOTE: All calculations of dates involving item master lead times are done using manufacturing days (M-days), not calendar days. For example, when the system deducts 10 days from an end date to arrive at a start date, it is actually counting back 10 M-days

Manufactured Items

The lead times for manufactured items are used to estimate job start dates and material requirement dates, which are essentially the same thing. That is, you need the material at the start of the job. The calculation used for manufactured items to arrive at a projected start date is the following. The .499 is added before the integer function (which rounds) is used so that it always rounds up to the next full day.
start date = end date – fixed lead – integer((var lead * qty / hrs per day) + .499)
The following functions use this calculation:
1) Job Creation
When you manually add a job, you must enter either the start or end date. Whichever you enter, the system arrives at the other using this calculation. When you use a system feature which creates a job, the end date defaults from the source record’s due date and the start is calculated using this formula.
Manually add a job
Firm a PLN to job from the MRP Detail Display
Firm MPS to job from the MPS screen
Add a production schedule release
X-ref and create a job from CO line item
X-ref and create an estimate job from an estimate line
X-ref and create job from a transfer order line item
X-ref and create job from project resource
2) MRP passing requirements
When a parent item has a PLN or and MPS receipt, the system passes it to the materials in the item’s current BOM to create PPLN and PMPS requirements for the materials. The date assigned to those requirements is calculated with the above formula using the MPS or PLN due date as the “end date”.
This calculation is also used to pass job requirements to the job’s BOM if the MRP parameter “Use Dynamic Lead Time” is No (or not checked). In that case, the item master lead times are deducted via the formula from the job’s “MRP End” date.
3) MRP Order Action report
The order action report reads through all planned orders and prints those that need to be released. The report deducts the item’s lead time from the planned order due date using the following calculation which differs from the one given above in that paperwork lead and dock-to-stock are both also deducted. The report prints the PLN if the resulting “Release Date” is less than the “Ending Date” entered on the option screen. The paperwork lead is included since that is time before the start of the job which must be accounted for when releasing planned orders. The dock-to-stock is included since the report uses the same calculation for purchased and manufactured items but while have no impact since it should be zero for manufactured items.
release date = PLN due date – fixed lead –
integer((var lead * PLN qty / avg hrs per day) + .499) –
dock-to-stock lead – paperwork lead.

Purchased Items

For purchased items, the lead times are used to either calculate a PO release date when starting from a due date or to calculate a PO due date when starting with release date. The specific functions which use lead times for purchased items in one way or another are the following:
1) MRP Order Action report to calculate Release Date
Used as described above for manufactured items. The variable lead is used in the calculation but will typically be zero for purchased items.
2) Firming a PLN from MRP
When you firm a planned order from the MRP detail display, the system deducts the item’s dock-to-stock lead time from the PLN due date to arrive at the PO line (or PO requisition line) due date. The PLN due date is the date you need to issue the material to the job so the dock-to-stock must be deducted from that date for the PO due date.
3) X-ref and create PO from a job material
Same logic as item 2 applies here. The dock-to-stock is deducted from the operation’s start date if not blank or the job’s start date if the operation’s is blank.
4) “Matl Chk FWD Sched” algorithm
Enabling the “Matl Chk FWD Sched” SFC parameter causes the scheduling routine to potentially move out the start date of operations if it determines that purchased, non-stocked materials cannot be available by the desired start date. If the material is not tied to a PO line item, determines when it can be available by adding the item’s lead times to the current date. (i.e. when can we have the material if ordered today?). If an item/vendor cross reference records exists for the item, the system uses the lead time from the number one ranked vendor. Otherwise, it uses item master lead times.
5) Calculating a “Release Date” displayed on reports
A handful of purchasing reports deduct the item’s fixed and paperwork lead times from the PO line due date and print the result in a “Release Date” column. The dock-to-stock is not deducted since it is assumed that it was already deducted from the true need date when arriving at the PO line due date. The reports which show this are the following:
PO Status
Purchase Requirements (if status is planned)
PO Requisition by Buyer
6) Calculating due date when manually adding PO
If you manually add a PO (or requisition) line and an item/vendor cross reference record exists for the item and the PO vendor, the default due date is calculated by adding the item vendor record’s lead time to the date listed below:
Regular PO line: adds item vendor lead to PO order date
Blanket PO release: adds item vendor lead to Rel Date entered
PO requisition: adds item vendor lead to Req Date
NOTE: Unlike the item master lead time field, the item vendor cross reference lead time should be expressed in calendar days, not manufacturing days. When used as described in this point and point 4 above, the item vendor lead is simply added to the one date to arrive at the other. That is, it does not count M-days as do the functions which utilize the item master lead times.
Transferred Items
For the item with a source of Transferred, the fixed and variable lead time fields are not used by the cross-site functionality. When the MRP module passes planned orders (PLNs) for a transferred item to the item’s supply site to become a TPLN requirement in that site, date assigned to that requirement is the due date of the PLN minus the Transit Time in the Inter-Site Parameter record. Also, when you firm the PLN into a transfer order the Transit time is also used for setting the line’s Schd Ship Date. The Schd Rcvd Date is set to the PLN’s due date and the Transit Time is deducted from the date to arrive at the Schd Ship Date.
However, the Order Action report does use the item master lead time to calculate the Release Date for PLNs. That release date is then used to determine if the PLN will display in the “Transfer Orders to be Firmed” section of the report. For that reason, it may be best to set the item master fixed lead time equal to the transit time from the item’s ship site for all transferred items.