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Manufacturing Labor Hours for Materials

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Explains how to view and edit manufacturing labor hours, and their associated costs, for in-house produced parts

There are two ways to view and edit the manufacturing labor hours for in-house produced parts:

  1. In the LABOR COST tab of the make-part proposal popup,
  2. In the Work Center column for make parts from the consolidated requirements material list.

While the first method is recommended initially, both options are outlined below.

Labor Cost Popup for Make-Parts

From the consolidated requirement material list, double-click on any row for a make part to bring the popup showing details of that planned make-part proposal.  Click on the LABOR COST tab to view the operations or work-centers involved in producing that part in-house.

Operations or work-centers are listed in the order in which they work on the part, initially read from a routing set-up in your SAP system.

  1. Click the + to add a new operation or resource, or the - to delete a work-center or resource. You can select a new work-center from the list by clicking in the "Resource" column and typing in part or all of the resource description or activity type code from SAP to search
  2. When you enter or select a resource the department or site and workcenter are displayed, if defined in your labor or resource pool. There are also columns, hidden in the screen shot above, for the resource's company and activity type
  3. Enter or edit the set-up and run hours per unit
    • The set-up time covers time to prepare, set-up and break down the machine, including any administrative tasks which are not dependent on the quantity of parts being produced. Set-up times are not subject to complexity, realization factors or learning curves
    • The run hours per unit covers the time to process one part on the machine, or rather the labor effort required from one person full-time to produce one unit of that part. Run hours goes up in proportion to the quantity of parts being produced in the lot-size, as well as based on complexity and learning curve or realization
  4. The total time is calculated as Set-up + ( Run Hrs/Unit x Qty on Additional Data x Complexity for the Part x Realization factor for the Operation )
  5. The complexity factor, if visible as a column, represents the overall complexity of the assembly so is the same for all operations. Complexity can only be edited in the additional data tab. The realization factor represents the efficiency of each operation or work-center to cover things such as learning curves and can be edited for each operation here. Both complexity and realization effects the total time as explained immediately above
  6. The rate/hr is read from the resource or labor pool and normally comes from SAP's activity type - cost center planning rate or a forward projection of this rate if not managed far enough into the future in SAP.  It can only be edited in the resource set-up. Total cost is the total time x rate
  7. The total effort or sum of total time for each operation is displayed at the top, as is the total cost
    • In this example each work-center rate is managed in USD but the delivering organization for this basis of estimate WBS is in Europe and is measured in EUR. Consequently the total cost is 255.28 Euro as opposed to $300

Labor Cost Work Center Columns for Make-Parts

There is a box "Show Wk Ctr Columns" highlighted in the screen image below which you can check to show up a column for each work-center or resource involved in producing ANY of the parts in your consolidated material requirements list, as shown below. The total hours for each work-center or resource and material or part is shown in each cell, for example:

  1. The total time for this part to be processed on work-center for ASSEMBLY is 289 hours. This time is the sum of set-up + ( run hrs/unit x qty x complexity x realization ) the same as would appear in the LABOR COST tab of the material proposal popup
  2. The total time for work-center PWA - CLINCH MACHINE is 388 hours. Note that these column headings are created dynamically by prefixing the work-center name with "WC_" for work-center. Double-clicking on any of these cells opens a new popup where you can edit just the set-up, run time, complexity factor or realization, as shown in the second screen shot below.
  1. Set-up can be edited similar to the Labor Cost tab in the material proposal popup outlined above
  2. Processing time or run hours/unit can also be edited similarly
  3. The quantity or lot-size being costed, plus the complexity or similar-to factor of this assembly, apply to the part as a whole not to an individual operation. They are displayed only in this popup
  4. The realization or learning curve factor can be edited here
  5. The total time (setup + run hrs/unit x qty x complexity x realization) is displayed as well as the standard total time (setup + run hrs/unit x qty). The standard total time is the total set-up + processing time ignoring complexity and/or realization factors
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