Add facility overhead (rent + utilities) to operating costs and pricing engine

Adds MonthlyRent, MonthlyUtilities, and MonthlyBillableHours to CompanyOperatingCosts so fixed shop occupancy costs are recovered on every quote. The pricing engine converts these into a per-hour rate and applies it as a transparent "Facility Overhead" line between oven batch cost and shop supplies. UI added in Company Settings Operating Costs tab and Setup Wizard Step 3; migration AddFacilityOverheadFields applied. Help docs and AI knowledge base updated to cover the new fields and the revised quote pricing calculation order. Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-04-24 19:35:00 -04:00
parent 813f76138c
commit 4153acf3aa
14 changed files with 9575 additions and 21 deletions
@@ -600,6 +600,7 @@ public static class HelpKnowledgeBase
        - Standard Labor Rate ($/hr)
        - Equipment hourly costs (oven, sandblaster, coating booth)
        - Powder cost per sq ft
+        - **Facility Overhead** — Monthly Rent ($), Monthly Utilities ($), and Monthly Billable Hours. These three fields let the system recover your fixed shop costs on every quote by adding a per-job overhead charge based on estimated labor hours.
        - General markup %
        - Tax %
        - Shop minimum charge
@@ -683,6 +684,20 @@ public static class HelpKnowledgeBase
        A percentage added to cover consumables: masking tape, hooks, racking supplies, touch-up powder, rags, etc. Applied as a percentage of the total material + labor cost.
        - Typical: 3–8%

+        ### Facility Overhead (Rent & Utilities)
+
+        **Monthly Rent ($)**
+        Your monthly shop lease or mortgage payment for the production space. Enter 0 if you own outright and have no occupancy cost.
+
+        **Monthly Utilities ($)**
+        Gas, electricity, and water for the shop per month. Do NOT include utility costs already captured in your oven or equipment hourly rates — that would double-count.
+
+        **Monthly Billable Hours (default: 160)**
+        The number of productive hours the shop operates per month. Default of 160 represents one full-time worker-equivalent (4 weeks × 40 hours). If you run two full-time workers, use 320. The system converts rent + utilities into a per-hour rate using: (Monthly Rent + Monthly Utilities) ÷ Monthly Billable Hours.
+        - Example: $2,000 rent + $800 utilities ÷ 160 hours = $17.50/hr overhead rate
+        - That rate × estimated job hours is added as "Facility Overhead" in the quote breakdown
+        - If both rent and utilities are $0, no overhead line is added to quotes
+
        ### Overhead & Profit

        **General Markup % (your profit margin)**
@@ -722,15 +737,17 @@ public static class HelpKnowledgeBase
        1. **Surface area** — calculated from the dimensions you enter (length × width × quantity, adjusted for shape), or entered manually
        2. **Powder material cost** — if an inventory item is selected: (item cost per lb ÷ (coverage rate × efficiency)) × surface area. If no item selected, uses the fallback Powder Cost Per Sq Ft from Operating Costs
        3. **Additional coats** — each additional coat adds more material cost + Additional Coat Labor % of base labor
-        4. **Shop supplies** — Shop Supplies Rate % × (material cost + labor cost)
-        5. **Labor cost** — Standard Labor Rate × estimated hours. Prep service modifiers: Sandblasting = 1.5× rate, Masking = 0.5× rate
-        6. **Equipment costs** — Oven, Sandblaster, Coating Booth each contribute their $/hr rate × estimated time
-        7. **Complexity adjustment** — the complexity multiplier % is added to the item subtotal
-        8. **General Markup** — applied as a multiplier on the running total (profit margin)
-        9. **Rush charge** — added if the job/quote priority is Rush or Urgent
-        10. **Customer tier discount** — if the customer has a pricing tier, their discount % is subtracted
-        11. **Tax** — Tax % applied to the subtotal (skipped for tax-exempt customers)
-        12. **Shop minimum** — if the total is below the Shop Minimum Charge, the minimum is used instead
+        4. **Labor cost** — Standard Labor Rate × estimated hours. Prep service modifiers: Sandblasting = 1.5× rate, Masking = 0.5× rate
+        5. **Equipment costs** — Oven, Sandblaster, Coating Booth each contribute their $/hr rate × estimated time
+        6. **Complexity adjustment** — the complexity multiplier % is added to the item subtotal
+        7. **Oven batch cost** — if a named oven is assigned to the quote, the batch cost is added based on the oven's hourly rate and cure cycle
+        8. **Facility overhead** — (Monthly Rent + Monthly Utilities) ÷ Monthly Billable Hours × total estimated job hours. Shows as a separate "Facility Overhead" line in the breakdown. Skipped if rent and utilities are both $0.
+        9. **Shop supplies** — Shop Supplies Rate % × (items subtotal + oven batch cost). Applied before facility overhead so supplies don't compound overhead.
+        10. **General Markup** — applied as a multiplier on the running total (profit margin)
+        11. **Customer tier discount** — if the customer has a pricing tier, their discount % is subtracted
+        12. **Rush charge** — added if the job/quote priority is Rush or Urgent
+        13. **Tax** — Tax % applied to the subtotal (skipped for tax-exempt customers)
+        14. **Shop minimum** — if the total is below the Shop Minimum Charge, the minimum is used instead

        **To get accurate quotes, you need:**
        - Operating Costs all filled in (Steps 3–4 of the wizard)
@@ -780,7 +797,7 @@ public static class HelpKnowledgeBase
        - Footer note (quotes and invoices only)

        **Operating Costs tab**
-        All pricing rates. See the "Operating Costs Field Guide" section above for full details.
+        All pricing rates including labor rates, equipment hourly costs, material costs, facility overhead (rent + utilities + billable hours), markup, and minimums. See the "Operating Costs Field Guide" section above for full details.

        **Named Ovens tab**
        Configure physical ovens for the Oven Scheduler. Each oven has a name, cost per hour, max load capacity (sq ft), and default cure cycle (minutes). The first oven's cost also updates the Oven Operating Cost rate used in quote pricing.