TABLE OF CONTENTS

Overview

Sub-costings enable the accurate costing of trims that vary by garment size. This ensures that material usage and costs reflect the actual requirements for each size variant of a product.


The size-level data captured through sub-costings is integrated into material requirements planning (MRP), allowing planners and buyers to place precise trim orders. This reduces waste, avoids shortages, and ensures production efficiency.


This approach is particularly important for trims that cannot be adjusted or cut to length, such as technical zippers that are manufactured in fixed, predefined sizes.


Sub-Costing can be enabled or disabled for each cost line within the Job BOM.

When Sub-Costing is enabled, the main Job BOM (generic item) displays the average unit consumption and cost derived from the size-specific trim data.

However, all reporting and material requirement outputs utilize the detailed size-level data, ensuring that planners and buyers receive accurate information on the actual quantities of trims required per size.


Pre requisite to adding Sub-Costing requires a generic & sized trims Cost Sub-Type items to be created in the Sync Admin Cost Library.

This generic item is added to the main Job BOM, while the size-specific trims are linked in the Sub-Costing. This structure ensures that costing and reporting remain integrated—maintaining a single parent cost line while accurately reflecting the detailed, size-based trim requirements.


When creating a PO for sized trims Sync will group the trim items by cost sub type code and then unit cost.


See Add Sub Costing FAQ for step by step

Example

For instance, a jacket style may require:

  • Size S: 55 cm zipper

  • Size M: 60 cm zipper

  • Size L: 65 cm zipper


  • Zipper (Generic)


By setting up sub-costings, each size’s zipper length and corresponding cost are recorded separately. Requirements reporting aggregates the correct number of each zipper length needed across the full size run—ensuring accurate supplier orders and preventing overstock of incorrect sizes.


Admin library of trims by size:

- Each trim by size should have a 'generic' code as well as a sized code for each trim by size

Ordering (PO's) of Trims by size:

- Trims by size orders must be placed against the sized trim & not the generic
- This enables receiving of the sized trim into stock rather than the generic

Stock holding of Trims by Size:

- The generic item should not be received into stock or have stock on hand (this may result in incorrect picking of the generic rather than the sized trim)
- Stock should be accurately received & kept for the sized trims only

Picking of Trims by Size:

- The generic trims should not be picked for production of finished goods
- Only the sized trims should be picked for production