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Manual Overrides & Governance

While automation provides speed and consistency, manufacturing expertise often requires "nudging" the numbers based on real-world constraints. Manual Overrides allow this flexibility while maintaining strict governance.

Why Overrides are Necessary

  • Shop Floor Reality: A machine may be underperforming or a specific operator may be exceptionally fast.
  • Supplier Volatility: Real-time RM rate changes that haven't hit the master data yet.
  • Strategic Pricing: Lowering margin for a high-volume "foot in the door" account.
  • Experimental Processes: Estimating a process the factory hasn't run before.

The Golden Rule of Overrides

"Any value can be changed, but every change must be justified and logged."

Override Workflow

  1. Identify: User clicks an "Override" icon next to a field.
  2. Input: User enters the new value (e.g., Cycle Time from 1.2h to 1.1h).
  3. Justify: A mandatory "Reason for Override" field appears.
  4. Apply: System recalculates the entire tree instantly.
  5. Log: Change is recorded in the Explainability trail and the Version History.

Level of Overrides

Scope Example Impact
Master Data Global RM rate update Affects all future quotes using that material.
Quote Level Specific Material Rate Affects only this quote (and its future versions).
Operation Level Specific Setup Time Affects only a single process step in the routing.

Visual Indicators

Standardized color-coding helps reviewers spot overrides instantly:

  • Regular Value: Standard font (Black/Gray).
  • Overridden Value: Bold Amber/Gold with a * indicator.
  • Reason Tooltip: Hovering shows "Estimator Rahul: Reduced cycle time for Op 2 based on previous similar job J-998."

Governance & Approval

For "Safe" costing, overrides above a certain threshold trigger an approval workflow:

  • Impact < 5%: Auto-approved.
  • Impact 5-15%: Flagged for senior estimator review.
  • Impact > 15%: Requires Manager approval before a PDF quote can be generated.

Impact on Accuracy

Overrides are a "double-edged sword." Frequent overrides on the same field suggest that the Master Data is out of sync.

System Insight: CostEngine periodically generates an "Override Frequency Report" to identify Master Data that needs updating.

"Machine CNC-01 is overridden in 80% of quotes. Its MHR in Master Data should likely be updated from ₹150 to ₹165."