A little more info needed, I think?
 
I assume you've double checked the BOM and Routing.
 
Where are the "cost of part and outside processing" coming from? i.e. where are they entered or on what report/screen do you see them?
 
Where are the "adding up to" numbers coming from? i.e. on what report/screen do you see them?

Evo is not very restrictive on these kind of issues.
 
My guess is that either the item was copied from a type R part, or was a type R part at one time.  
 
Do this to see what Evo erroneously allows: (all in IN-B) change a part from type A/F to R. Now enter a material cost, roll up cost and save. Change part type back to A/F - still has a "this level material cost". Hint - you can fix the problem that way - change them to R, set Material Cost to 0 and change back to A.
 
Should be easy enough to create a report for all A/F parts with a "This level material cost" of >0.