Calculation (Actual)

Actual calculations reflect the true costs incurred based on posted values. When Multi-Level Calculation is enabled, actual calculations can include all posted costs across all subordinate production order levels.

Before you can create an actual calculation, the production levels must be completed and the item or parts of it must have been produced. Only then can an actual calculation be run.

To include the sub-levels in a multi-level calculation, the production order must have multiple levels. To make sure that multi-level production orders are created, set the following on the Item Card of each item that has a production BOM:

Replenishment System = Prod. Order on the Replenishment FastTab
Reordering Policy = Order on the Planning FastTab

You can create actual calculations for production orders with the following statuses:

Released
Finished

Actual calculations include all posted values for production order lines.

Calculation Process

When Multi-Level Calculation is enabled for an actual calculation, the calculation follows the multi-level production order structure:

Components that are supplied by another production order line are calculated through that production order line.
Posted material consumption is calculated across all production order levels.
Posted capacity costs and routing operations are included for all production order levels.
The calculation reflects the actual costs incurred.

Cost Accuracy Considerations

Cost deviations may occur when demand is summarized at multiple levels.

Example:
If products A and B both require the same semi-finished product and the demand from both orders is summarized into a single order for the sub-assembly, the actual cost calculation might be affected by rounding issues when allocating costs back to products A and B.

For accurate cost tracking in multi-level scenarios, consider the following:

Create separate orders for unique demands when possible.
Review calculations at each level to identify potential rounding impacts.
Use expected calculations to establish cost baselines.

Create Actual Calculations

You can create actual calculations for the main production level or for sub-assemblies.

To create an actual calculation for the main production level

Open the production order.
On the Lines FastTab, choose Line > Calculation > Calculation (Actual).
- If concurrent calculations are used, the actual calculation is automatically created and assigned to the production order and concurrent calculation.
- If no calculation exists for the production order line, the Calculations page opens. Choose the New action to create a calculation. You can create more than one calculation for one production order line.
If the Standard Calc. Schedule No. field is filled in on the item, the standard calculation schedule is applied automatically. Otherwise, the Calculation Schedules page opens for you to select a calculation schedule.

The values from the production order line are transferred to the calculation header.

To create an actual calculation for sub-assemblies

You can create an actual calculation for a specific sub-assembly in the production order.

Open the production order.
Select the line of the sub-assembly production order to be calculated.
On the Lines FastTab, choose Line > Calculation > Calculation (Actual).
If no calculation exists, the Calculations page opens. Choose the New action to create a calculation.
Select the calculation schedule to use for the calculation.

Note

When you create a calculation card, the item group of the production sub-assembly is selected.

Integration with Discrete Manufacturing

When using Multi-Level Calculation with COSMO Discrete Manufacturing, actual calculations can be created for production orders generated from Document BOMs and Construction Orders. For detailed procedures and automatic activation behavior, see Multi-Level Calculations in Discrete Manufacturing.

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