Table of Contents

Mixed Assembly and Manufacturing Items

Multi-Level Calculation works with assembly items that include manufacturing items in their BOM. This allows you to calculate assembly items where some components require production BOMs and routing operations.

Note

Multi-Level Calculation supports both manufacturing items with nested production BOMs and assembly items with manufactured components. For information about multi-level calculations with manufacturing items, see Multi-Level Manufacturing Calculations.

Scenarios

Use Multi-Level Calculation with assembly items when:

  • The top-level item is assembled (Replenishment System = Assembly)
  • One or more components in the assembly BOM are manufactured items (Replenishment System = Prod. Order)
  • You need to include the manufacturing costs (material + routing) of those components in the overall assembly cost

Calculation Process

When Multi-Level Calculation is enabled for an assembly item, it recognizes components with Replenishment System = Prod. Order and automatically performs the following:

  • Processes the component's production BOM
  • Calculates routing operations for the manufacturing item
  • Recursively processes any subordinate manufacturing items
  • Includes all material and capacity costs in the parent assembly calculation

You only need to create one calculation for the assembly item. Multi-Level Calculation handles all manufacturing components automatically.

Example BOM Structure

The following example shows an assembly item with manufacturing components:

Assembly Item (Top Level)
├── Assembly Component A (Purchase)
├── Manufacturing Item B (Prod. Order)
│   ├── Production BOM for Item B
│   │   ├── Raw Material C
│   │   └── Manufacturing Item D (Prod. Order)
│   │       └── Production BOM for Item D
│   │           ├── Raw Material E
│   │           └── Raw Material F
│   └── Routing for Item B
└── Assembly Component G (Purchase)

When you create a calculation for the Assembly Item with Multi-Level Calculation enabled:

  • The assembly BOM is processed
  • Manufacturing Item B's production BOM and routing are calculated
  • Manufacturing Item D is recursively processed
  • All material costs and routing operations across all levels are included

Setup Requirements

Assembly Item (Top Level):

  • Set Replenishment System to Assembly
  • Configure assembly BOM with all components

Manufacturing Components:

  • Set Replenishment System to Prod. Order
  • Assign a production BOM in the Production BOM No. field and make sure its Status is Certified
  • Configure routing if capacity costs are needed

Calculation Card:

  • Enable the Multi-Level Calculation field on the General FastTab

Troubleshooting

If you encounter issues with multi-level calculations for assembly items, review the following solutions.

Manufacturing Component Not Calculated

Verify the following:

  • Multi-Level Calculation is enabled on the Calculation Card
  • The manufacturing component has Replenishment System = Prod. Order on the Item Card
  • The manufacturing item has a production BOM assigned in the Production BOM No. field, and its Status is Certified

Production BOM Not Certified

Verify the following:

  • The manufacturing item has a production BOM assigned in the Production BOM No. field, and its Status is Certified
  • If you use BOM versions, the appropriate version is certified and active for the calculation date

Costs Not Reflecting Expected Values

Verify the following:

  • All routing operations are assigned to the manufacturing items
  • Scrap percentages at each BOM level are correct, because they compound in multi-level calculations

See Also

Multi-Level Calculation Setup


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