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Work-order true cost simulator

Model a build before you run it: material, labour and scrap by operation, and what a unit actually costs against what your standard says.

Nothing you type is sent anywhere
The build
Order quantity
{{qty}}
Material per unit
{{cur}}{{mat}}
Routing
Scrap at a late operation destroys everything spent before it. That is the whole point of this tool.
{{o.name}}
cumulative {{o.cum}} / unit
Labour + overhead {{o.cost}}
Scrap at this operation {{o.scrap}}%
Scrap your standard cost assumes
The number in the item record, not what actually happens
{{std}}%
USD
INR
Actual cost per good unit
{{actual}}
vs {{standard}} standard
{{verdict}}
{{good}}
good units out of {{qty}}
{{lost}}
value destroyed this run
Where the money is lost
{{l.name}}{{l.value}}
What this says

{{insight}}

How this is worked out

Material
Issued in full at the start of the order, so a unit carries its whole material cost from operation 10 onward.
Labour and overhead
Applied to the units that actually enter each operation, not to the order quantity, you do not pay to machine something you already scrapped.
Value destroyed
Units scrapped at an operation, multiplied by everything spent on them up to and including it. This is the number the shop floor never sees.
Standard cost
Gross cost divided by one minus the scrap percentage your item record assumes, which is how a standard is normally grossed up.

A simplification worth naming: this assumes scrap is detected at the operation that caused it. Where it is found later, the loss is larger still, because more cost has been added in between.

The same thing, on your dashboard

Deployed, this stops being a page you visit. It becomes a portlet on the dashboard the people who need it already open every morning, reading your real records instead of numbers you type, next to the KPIs and lists they are already looking at. The amber portlet below is the only part of this screen that is ours.

HomeActivitiesTransactionsListsReportsAnalyticsSetupCustomizationPlant manager · ProdWork orderOperationsCostingWork order WO-4471Transactions › Manufacturing › Cost simulationAdd portletPersonalizeORDERED500Assembly ASM-100GOOD UNITS45644 scrappedACTUAL PER UNIT$223Standard says $210VALUE DESTROYED$7,621Across four operationsCOST ACCUMULATING THROUGH THE ROUTING, PER UNITRefresh24018012060005101520303540QCSTANDARDOPERATIONS AND SCRAPView allOPERATIONSCRAPCOST LOST10 · Cut1.0%$196NORMAL20 · Weld2.0%$742WATCH30 · Machine3.0%$4,118WORST40 · Assemble2.5%$2,565HIGHWORK ORDER TRUE COSTAtsoviaACTUAL COST PER GOOD UNIT$223Standard$210 / unitVariance+6.2%Worst operation30 · MachineReads the BOM and routing. Writes nothing.REMINDERSOrders over standard cost14Operations above scrap target2Routings missing scrap %6

Illustrative layout, and deliberately not a copy of any vendor's interface, no borrowed logo, wordmark or colour identity. The real thing inherits whatever theme, tabs and role permissions your account already uses, so on your screen it will wear your colours rather than ours.

Run it on your own account
Want this run against your actual NetSuite account?
We will run the same analysis on your account, read-only, and send you the result with the three things worth doing first. No obligation, and nothing is changed in your account.
One email. We do not add you to a mailing list.

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