To all with costing questions and comments on the rollup problems, here is some general info that might

help several situations: First, the cost rollup programs: 1) CST500 says "cost set rollup". It actually only rolls up the bill of material. It does not calculate costs from routings. 2) CST600 says "load standards from routings". It actually performs two functions. First, it calculates labor and overhead based on routings & workcenters, then calls CST500 to "rollup" material, labor and overhead costs. When most people refer to the BPCS "cost rollup" process, they are referring to the CST600 process. Second, the setup and system parameters. 1) System Parameters: If you have the cost system parameters set for facility specific costs = Y (SYS800-08), you must have facility specific routings defined. You can have either facility specific bills of material or global bills of material. If you have the cost system parameters set for facility costs = N, then you MUST have GLOBAL bills of materials and GLOBAL routings. (note: planning bills are not facility specific....) The most likely cause of the no cost rollup problem is that you have the costing parameter set to global costs, but you have facility specific bills and routings. 2) As mentioned in one response, method codes can also come into play. The B/M and routing method codes used during cost rollup are defined on the cost set. However, there is a hierarchy that is followed. For example, if the cost set says to use B/M routing "EX", and "EX" does not exist, it will look next for either a facility specific or global b/m (depending on the system parameters.). 3) In order for CST600 to generate labor and overhead, you must define standard rates in a workcenter (CAP100) and hours required in a routing (SFC100). (The routing needs to be facility specific or global depending on the system parameters). 4) In order for CST500 to roll up material costs, you must define the standard cost for all purchased raw materials used on the B/M (CST100). If you are doing facility costing, these need to be facility specific. If you are doing global costing, these need to be global. You also need to define a B/M. Finally, the files. 1) CMF is the cost master file. It stores all the specific costs by item, cost set, and cost bucket (and also by facility if the parameter is set to facility specific costing). You can see data in CMF via the CST300 inquiry. Total cost by item(by facility) is stored in cost bucket 0. 2) CIC is the old facility cost file, and the current Item/Facility planning data file. It stores total item cost by

facility for cost sets 1 - 4. If a CIC record doesn't already exist, it will get created when a facility specific BOM is created during BOM500. It will also get created when you create a facility specific routing (SFC100). CIC records ARE NOT required for either the CST500 or CST600 process (at least at as of BPCS 405CD REL02). However, if you have a situation where you have facility specific costing, but no CIC records, you could encounter some "incorrect" calculations in the cost rollups. The batch size in CIC is the B/M batch size used by CST500, and the lot size in CIC is used to allocate setup costs defined on the routings in CST600. If you have facility specific B/M and routings, but no CIC records, I suspect it is because you converted data or loaded it from a source outside of BPCS. Let me know if I can be of further assistance. Peggy Heritz Senior BPCS Specialist Crowe, Chizek & Company, LLP http://www.crowechizek.com/scg/ phone: 219.236.8698 fax: 219.236.7 Read more at: http://archive.midrange.com/bpcs-l/200003/msg00098.html midrange.com

You might check BPCS_L archives, since there has been a LOT of traffic on BPCS costing topics, although not a lot recently. If you look in INV300 F21 filter on # (pound or number sign) what you are seeing is the history of cost changes to the item via CST100. I find it easier to navigate cost complexities by using the terminology of COST DIMENSIONS: Buckets; Sets; Types, Levels, Facilities, Bugs, Perceptions & Expectations We can have the same item in more than one facility, with different costs. IIM Item master file contains cost by item, but depending on System Parameter settings (ZPA file controlled by SYS800 settings) some programs extract cost not from IIM but from CIC summary or CMF detail There are 2 cost levels ... this and previous (child items) There can be up to 99 sets defined by CST140 (stored in CSM file) ... start with standard actual, add frozen, various kinds of simulated ... I have suggested we add "physical" which would be a copy of standard costs as of the last physical inventory, so if the auditors ask 6 months later "What was the cost of this item AS OF the time of the physical?" or "How has this cost changed between time of physical inventory and today?" easier to deliver.

There can be up to 999 buckets defined by CST150 & stored in CBU file ... think accumulated totals where bucket zero is the total of all the other buckets typically material labor overhead and granularization of this for example we have some raw material whose pricing is volatile. At one time we wanted to be able to show how much of our material content was that material so as to see the impact on the bottom line when the raw material price fluctuated Beware of cost buckets not adding up correctly to bucket zero. There are BPCS programs where you not get to see bucket zero. An important aspect of cost buckets is how we define what bucket rolls to what bucket There can be up to ? types ... I think this is set by BPCS without the option of parole ... think controls over how activity flows into the cost bucket dimension typically labor machine setup material can be broken into types of material depending on industry, can include stuff like electricity In our case Bucket 4 is Machine but type 2 Labor We have a cost bucket that is the total costs in one facility, transferred to another facility, that rolls to material Other files referenced when BPCS calculates costs CEM employee clock file used for costing some labor CIC cost plan item by facility CMF cost master LWK work center master used for costing some labor and overhead We are BPCS 405 CD mixed mode, costing by facility. We have had bad data showing up in our costs by facility when the global cost is populated, with something different than the facility cost. It seems like it adds the global to the facility total. At one time any time an engineer updated an item, they would do a cost rollup on that item's BOM. Then we learned that if two or more people doing this at same time, mutual crash, because BPCS assumes only one person at a time doing this, it messes with all components, all where-used, all items "networked" to the one being rolled up, so if two people messing with some of the same items in this way, the math not come out right. We have a facility that is purely distribution ... we buy parts for resale. This facility is not supposed to have any production costs. At one time we had a facility that manufactured parts that were used as raw materials in another facility.

Thus, the cost dimensions structure was not identical across facilities ... the cost rules varied by facility. When you transfer an item in BPCS across facilities, it carries with it all the cost ingredients from the other facility. So we have this item in the distribution facility and it has no labor costs. The same identical item is in the manufacturing facility, and it has labor costs. Someone transfers some excess stock from the manufacturing facility into the distribution facility. Now it has labor costs in the distribution facility. Some people might call this a bug, because they want to make it easier to move quantities, without moving the costs associated with those quantities. The shop order purge processes cost updates in the sequence of the shop order#s that have been completed, which can result in some bogus costs. Suppose we release a shop order to make part 123 which has component assemblies 123A 123-B 123-C etc. This might end up with shop order #s 30,001 for end item 123 and shop orders AFTER 30,001 for the sub-assemblies If the work all gets finished on the same day, then the shop order purge updates the cost for shop order 30,001 BEFORE the costs of the items that went into that shop order. Our parts are not made smoothly ... we might have a small order with high unit costs, alternating with larger quantity production, with lower unit costs. This pattern, combined with shop order purge not processing closed orders in BOM where used sequence, results in our actual costs spiking to an excess. Some people might label this as being a bug in BPCS At our version, BPCS costing, and other areas have some bugs with respect to rounding errors, especially when using what IBM calls extreme values like zero and one. This may have been fixed in later versions. Basically the problem is that numeric values in RPG go up to 15 positions, with up to 9 decimal ... if you do math with maximum size fields, RPG needs some other logic to handle the odd digits that could fly outside of the 15 wide, even temporarily. BPCS does not do so, which according to the IBM manual can have unpredictable results. We reported this bug when we were still on OSG and were told that's the way it is supposed to work. The bug does not bite us very often, except through CST900 actual production cost purge. Typically it causes previous level of actual cost to be off by plus or minus 0.00001 ... in a few cases it drives the cost negative, and we have had a tiny number of instances of it driving a cost that should be something like XX.X to 9999999999.99999 or

9999999999.99998 plus or minus (because the unpredictable results include the number "wrapping around zero and infinity" We are using BPCS V6.0.02. I have set up an item with both setup time and machine time in the routing. I am using a basis of per 100. Also, I have established a lot size for this item in the Item Master. When I perform a cost rollup and produce the costing sheet, the correct cost is shown for the setup and machine time based on the established overhead rate. The cost in the bucket for the parent item as well as the total standard cost incorrectly includes the total setup cost for the entire lot. What are all the parameters that affect the cost calculation? At one time, facility specific costing was turned on. It has now been turned off. Not sure if this could be part of the issue. To date, all costs have been loaded either by an upload from MIS or through CST100. The cost roll process has not been used. Read more at: http://archive.midrange.com/bpcs-l/200510/msg00005.html midrange.com