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11-1
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10. Life-cycle costs are all costs associated with then taken to achieve this goal— usually by
the product for its entire life cycle. These seeking ways to reduce costs to the point
costs correspond to the costs of the activities where the plan becomes feasible (often by
associated with the production life cycle: seeking better product designs). This is
research and development, production, and consistent with the cost reduction emphasis
logistics. found in life-cycle cost management.
11. The four stages of the consumption life 14. Cells act as a “factory within a factory.”
cycle are purchasing, operating, Each cell is dedicated to the production of a
maintaining, and disposal. Post-purchase single product or subassembly. Costs
costs are those costs associated with associated with the cell belong to the cell’s
operating, maintaining, and disposing of a output. By decentralizing services and
product. Knowing these costs is important redeploying equipment and employees to
because a producer can create a the cell level, the quantity of directly
competitive advantage by offering products attributable costs increases dramatically.
with lower post-purchase costs than
15. Backflush costing is a simplified approach to
products offered by competitors.
accounting for manufacturing cost flows. It
12. Agree. According to evidence, ninety percent uses trigger points to determine when costs
of a product’s costs are committed during the are assigned to inventory or temporary
development stage. Furthermore, $1 spent accounts. In the purest form, the only trigger
during this stage on preproduction activities point is when the goods are sold. In this
can save $8–$10 on production and variation, the manufacturing costs are
postproduction activities. Clearly, the time to flushed out of the system by debiting Cost
manage activities is during the development of Goods Sold and crediting Accounts
stage. Payable and Conversion Cost Control.
Other trigger points are possible but entail
13. Target costing is the setting of a cost goal
more journal entry activity and involve some
needed to capture a given market share and
inventory accounts.
earn a certain level of profits. Actions are
11-2
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accessible website, in whole or in part.
CORNERSTONE EXERCISES
*Based on the new demand, the number of clerks can be reduced by one,
saving $45,000 (10,500/5,000 implies the need for three clerks).
3. Since each purchasing agent can process 5,000 orders, only two agents are
needed, saving an additional $45,000 of salary costs. Variable purchasing
costs would also drop by an additional $1,600 [$0.80 × (10,500 – 8,500)].
Thus, total savings would increase by $46,600, and the new price would
decrease by an additional $0.93 ($46,500/50,000) to $8,877.66*
Bid price:
Either customer category = [$50 + ($1,375,500/350,000)] × 1.40 = $75.50
Yes, the new price based on quantity discounting incentives is lower than the
original bid price and so the original bid price could be offered without
decreasing profits under this new structure.
Cornerstone Exercise 11.4
1.
Design A Design B
Direct materialsa......................................... $ 6,000,000 $ 5,500,000
Conversion costb....................................... 5,000,000 12,000,000
Total manufacturing costs........................ $11,000,000 $17,500,000
Units produced.......................................... ÷ 25,000 ÷ 25,000
Unit cost..................................................... $ 440 $ 700
a
$20 × 300,000; $20 × 275,000
b
$100 × 50,000; $100 × 120,000
Logistical and post-purchase activities are not considered in this analysis.
2.
Design A Design B
Direct materials.......................................... $ 6,000,000 $ 5,500,000
Direct labora................................................ 750,000 1,800,000
Machininga.................................................. 3,750,000 4,500,000
Purchasinga................................................ 300,000 225,000
Setupsb........................................................ 1,800,000 600,000
Warrantyb.................................................... 500,000 125,000
Total product costs................................... $13,100,000 $12,750,000
Units produced.......................................... ÷ 25,000 ÷ 25,000
Unit cost..................................................... $ 524 $ 510
Post-purchase costs b................................ $ 50,000 $ 12,500
a
$15 × 50,000; $15 × 120,000; $75 × 50,000; $75 × 60,000; $150 × 2,000; $150 ×
1,500
b
$3,000 × 600; $3,000 × 200; $500 × 1,000; $500 × 250; $25 × 2,000; $25 × 500
ABC assigns manufacturing costs using both unit and non-unit drivers. It
also considers the effects of manufacturing, logistical, and post-purchase
activities (unit-based uses only manufacturing activities).
3. The post-purchase cost is $250,000 ($10 × 25,000) for A and $1,000,000 for B
($40 × 25,000). Although this cost is not paid for by the firm, it makes the total
cost of A less than B, and A becomes the environmentally cleaner product of
the two, better meeting the “green” product objective. Since both products
meet the target cost, A is the better strategic investment.
Cornerstone Exercise 11.5
1.
Transaction Traditional Journal Entries
1. Purchase of Materials Inventory.................... 600,000
raw materials Accounts Payable................ 600,000
2. Materials Work-in-Process Inventory....... 600,000
issued to Materials Inventory.............. 600,000
production
3. Direct labor Work-in-Process Inventory....... 90,000
cost incurred Wages Payable..................... 90,000
4. Overhead Overhead Control...................... 625,000
cost incurred Accounts Payable................ 625,000
5. Application Work-in-Process Inventory....... 585,000
of overhead Overhead Control................. 585,000
6. Completion Finished Goods Inventory........ 1,275,000
of goods Work-in-Process Inventory. 1,275,000
7. Goods are Cost of Goods Sold.................. 1,275,000
sold Finished Goods Inventory. . 1,275,000
8. Variance is Cost of Goods Sold.................. 40,000
recognized Overhead Control................. 40,000
Transaction Backflush Journal Entries: Variation 1
1. Purchase of Raw Materials
raw materials and In Process Inventory....... 600,000
Accounts Payable................ 600,000
2. Materials
issued to No entry
production
3. Direct labor Combined with OH: See next entry.
cost incurred
4. Overhead Conversion Cost Control.......... 715,000
cost incurred Wages Payable..................... 90,000
Accounts Payable................ 625,000
5. Application No entry
of overhead
6. Completion Finished Goods Inventory........ 1,275,000
of goods RIP Inventory........................ 600,000
Conversion Cost Control.... 675,000
Cornerstone Exercise 11.5 (Concluded)
Transaction Backflush Journal Entries: Variation 1
7. Goods are Cost of Goods Sold.................. 1,275,000
sold Finished Goods Inventory. . 1,275,000
8. Variance is Cost of Goods Sold.................. 40,000
recognized Conversion Cost Control.... 40,000
(b) No entry for Transaction 1; Entries 6 and 7 are replaced with the
following:
Cost of Goods Sold....................................... 1,275,000
Accounts Payable.................................... 600,000
Conversion Cost Control......................... 675,000
EXERCISES
Exercise 11.6
1. The total product consists of all tangible and intangible benefits. These
include the computer, its features, its operating capabilities, maintainability,
product reputation, service, and service reputation.
Exercise 11.7
Exercise 11.9
Inspecting products, reworking products, and warranty work: These are all
quality-related activities. This suggests a strategic change in the organizational
activity, “providing quality,” (an executional activity). The associated executional
cost driver is quality approach. The cost of all three quality activities can be
reduced by changing the driver from acceptable quality level (AQL) to total
quality management (TQM). TQM emphasizes zero defects. As the organization
strives to achieve a zero defect stage, the demand for inspecting products,
reworking, and warranty work diminishes. As less activity demand occurs,
resource spending on these activities can be reduced. Changes in other
organizational activities may also bring about cost reductions. Both “using
employees” (executional activity) and “grouping employees” (structural activity)
can be beneficial. Multitask training and strong employee involvement can
produce reductions in the cost of the three quality-related activities. Teams,
known as quality control circles, can be beneficial.
Moving materials: The driver is distance moved. This suggests that some
attention needs to be given to the executional activity of providing plant layout.
The driver is plant layout efficiency. Changing to a cellular format could bring
about significant reductions in the cost of materials handling.
Purchasing parts: This activity is driven by the number of different parts. This is
a driver that also relates to complexity, a structural activity. This suggests that
reducing complexity will reduce the number of different parts needed and the
cost of the purchasing activity. Additionally, the cost of this activity can be
reduced by selecting the JIT process technology with its methods that reduce the
need for parts inventories.
Storing goods and materials: Reducing days in inventory reduces the cost of this
activity. This suggests the possibility of looking at the structural activity:
selecting and using process technologies. There are process technology choices
such as JIT and theory of constraints that produce very low levels of inventory.
Expediting orders: Reducing the number of late orders (increasing the number of
on-time deliveries) will reduce the cost of this activity. This suggests a need to
decrease production time, perhaps by looking at organizational activities such as
plant layout and providing capacity. Increasing plant layout efficiency can
decrease cycle time. Utilizing capacity efficiently can also decrease the number
of late orders.
Exercise 11.10
1. Supplier cost:
First, calculate the activity rates for assigning costs to suppliers:
Inspecting carburetors: $180,000/4,500 = $40 per sampling hour
Expediting work: $144,000/300 = $480 per order
Reworking products: $1,026,000/4,500 = $228 per rework hour
Warranty work: $1,800,000/6,000 = $300 per warranty hour
Next, calculate the cost per component by supplier:
Supplier cost:
Harvey Curtis
Purchase cost:
$64 × 40,000.......................... $ 2,560,000
$57 × 120,000........................ $ 6,840,000
Inspecting carburetors:
$40 × 90................................. 3,600
$40 × 4,410............................ 176,400
Expediting work:
$480 × 30............................... 14,400
$480 × 270............................. 129,600
Reworking products:
$228 × 270............................. 61,560
$228 × 4,230.......................... 964,440
Warranty work:
$300 × 300............................. 90,000
$300 × 5,700.......................... 1,710,000
Total supplier cost.................... $ 2,729,560 $
9,820,440
Units supplied............................ ÷ 40,000 ÷ 120,000
Unit cost..................................... $ 68.24* $ 81.84*
*Rounded to the nearest cent.
The difference dramatically favors Harvey; furthermore, when the price
concession is considered, the difference is even greater, With the discount
and the 120,000 unit commitment, the unit cost of Harvey is $61.41 [$60 +
($2,729,560 - $2,560,000)/120,000)], which is much less than the Curtis
carburetor. Jackson should give serious consideration to accepting the
contractual offer made by Harvey given the savings will easily be more than
$1 million.
Exercise 11.10 (Concluded)
2. To assign the lost sales cost, it would be helpful to know the number of
defective units using the Harvey carburetor versus those using the Curtis
carburetor. Warranty hours would act as a very good substitute driver. Using
this driver, the rate is $3,300,000/6,000 = $550 per warranty hour. The cost
assigned to each component would be:
Harvey Curtis
Lost sales:
$550 × 300............... $165,000
$550 × 5,700............ $3,135,000
This increases the cost of the Curtis carburetor by $3,135,000/120,000 =
$26.13.*
*Rounded to the nearest cent.
Exercise 11.11
Frequent Infrequent
Processing sales orders:
$100 × 21,000........................... $ 2,100,000
$100 × 2,100............................. $ 210,000
Scheduling production:
$30 × 36,750............................. 1,102,500
$30 × 5,250............................... 157,500
Setting up equipment:
$120 × 26,250........................... 3,150,000
$120 × 5,250............................. 630,000
Inspecting batches:
$160 × 26,250........................... 4,200,000
$160 × 5,250............................. 840,000
Total customer cost..................... $10,552,500 $ 1,837,500
Profitability:
Frequent Infrequent
Sales revenue................................ $46,305,000 $ 46,305,000
Less: Other costs......................... 24,696,000 24,696,000
Customer-related costs.... 10,552,500 1,837,500
Customer profitability $11,056,500 $ 19,771,500
This outcome reveals that customers who place smaller, more frequent
orders are not as profitable as believed. To increase profitability of this
segment, management may consider the possibility of imposing a charge for
orders below a certain size, thus reducing the demands on the four customer-
related activities with a subsequent reduction in cost. Another possibility is
to offer quantity discounts to encourage larger orders.
Exercise 11.12
a. Inspection costs..................................................... DT DA
b. Power to heat, light, and cool plant..................... AL AL
c. Minor repairs on production equipment.............. DT DA
d. Salary of production supervisor (dept./cell)....... AL DA
e. Oil to lubricate machinery..................................... DT AL
f. Salary of plant supervisor..................................... AL AL
g. Costs to set up machinery.................................... DT DA
h. Salaries of janitors................................................. AL AL
i. Power to operate production equipment............ DT DTa
j. Taxes on plant and equipment............................. AL AL
k. Depreciation on production equipment.............. DT DA
l. Raw materials......................................................... DA DA
m. Salary of industrial engineer................................. DT DAb
n. Parts for machinery............................................... DT DA
o. Pencils and paper clips for production
supervisor (dept./cell)........................................... DT DA
p. Insurance on plant and equipment...................... AL AL
q. Overtime wages for cell workers.......................... DT DA
r. Plant depreciation.................................................. AL ALc
s. Materials handling.................................................. DT DA
t. Preventive maintenance........................................ DT DA
a
DA, if each cell has a meter.
b
Assumes engineers are assigned to cells.
c
Some might argue that cell square footage would be a good driver so this is now
DT. (We now know how much space is dedicated to each product.)
Exercise 11.14
3. The JIT cost is more accurate because maintenance cost is directly traced to
each product. There is no need to use an activity driver such as maintenance
hours to assign this cost to each product. This improved traceability can be
explained by two factors: multitask training and decentralization of services.
Exercise 11.15
Exercise 11.17
Exercise 11.18
1. Fabrication Assembly
Allocation ratio*............................ 0.25 0.75
Maintenance:
0.25 × $480,000........................ $120,000
0.75 × $480,000........................ $360,000
Direct overhead costs................. 720,000 204,000
Total......................................... $ 840,000 $ 564,000
*Allocation based on number of tests.
3. JIT manufacturing should result in more efficient production, and thus, costs
would be reduced. For example, the multidisciplinary nature of cells would
virtually eliminate the Inspection Department, producing significant savings.
Other savings such as elimination of most materials handling cost due to the
cell structure would also be realized.
CPA-TYPE EXERCISES
Exercise 11.19
Exercise 11.20
Exercise 11.21
c. The key is selecting a driver that is the best measure of consumption. Order
processing costs will be affected by the number of orders and is the most
logical choice. Pounds, revenues, and customer type all fail to capture the
order frequency and thus would not be good drivers for assigning order-filling
costs.
Exercise 11.22
a. The cost per defective component is $20 ($3,000,000/150,000). Thus, the cost
of each supplier increases because of the defective components: $2,700,000
for Day and $300,000 for Larsen (making “a” the correct answer). Larsen has
the lowest increase of cost because it has fewer defective units and appears
to be of higher not lower quality.
Exercise 11.23
d. The second stage assigns activity costs to cost objects. Since customers are
the cost object, the only correct answer is d.
PROBLEMS
Problem 11.24
Receiving:
Change in demand for purchasing = 250 – 100
= 150 component types
Change in steps demanded = 150/20 = 7.5, thus requiring 8 steps (partial
steps cannot be acquired)
Change in variable activity cost = 150 × $2,000
= $300,000
Change in step-fixed cost = 8 × $50,000
= $400,000
Total change = $300,000 + $400,000 = $700,000
The engineers did not have a correct view of the existing internal linkages. To
exploit internal linkages, it is imperative that internal value-chain activities be
identified with their associated cost drivers.
Problem 11.24 (Concluded)
4. The cost of producing decreases by $250,000 for the rejected design:
Unit-level activities:
Unit-level cost change = (260,000 – 250,000) × $30
= 10,000 × $30
= $300,000
Setups:
Setup cost change = (10,000 – 20,000)/2,000
= 5-step reduction × $90,000
= $(450,000) savings
Receiving:
Purchasing demand change = (75 – 100) = (25)
Decrease in steps = 25/20 = 1 (rounded down to nearest whole unit)
Decrease in variable activity cost = $2,000 × (25) = $(50,000)
Decrease in step-fixed cost = $50,000 × (1) = $(50,000)
Total change = $300,000 – $450,000 – $50,000 – $50,000
= $(250,000)
The rejected design actually produces a $250,000 savings relative to the
current design. Relative to the accepted new design, the savings is
$1,600,000 more! This emphasizes the importance of having the facts correct
when making strategic changes. ABC links output with activities and
activities with costs. Thus, any change in product design with an impact on
activities could be associated with cost changes. By describing cost
behavior better and
establishing the indicated linkages, ABC can help a manager identify the best
cost reduction strategies.
Problem 11.25
1. Supplier cost:
First, calculate the activity rates for assigning costs to suppliers:
Testing engines: $264,000/1,100 = $240 per engine
Reworking products: $440,000/5,500 = $80 per rework hour
Expediting orders: $330,000/110 = $3,000 per late shipment
Repairing engines: $594,000/1,375 = $432 per engine
Next, calculate the cost per engine by supplier:
Supplier cost:
Villa Verity
Purchase cost:
$297 × 10,800.......................... $ 3,207,600
$330 × 2,400............................. $792,000
Testing engines:
$240 × 1,089............................. 261,360
$240 × 11.................................. 2,640
Reworking products:
$80 × 5,390............................... 431,200
$80 × 110.................................. 8,800
Expediting orders:
$3,000 × 108............................. 324,000
$3,000 × 2................................. 6,000
Repairing engines:
$432 × 1,342............................. 579,744
$432 × 33.................................. 14,256
Total supplier cost....................... $4,803, 904 $823,696
Units supplied.............................. ÷ 10,800 ÷ 2,400
Unit cost........................................ $ 444.81* $ 343.21*
*Rounded to the nearest cent.
The Verity engine costs less when the full supplier effects are considered.
This is a better assessment of cost because it considers the costs that are
caused by the supplier due to poor quality, poor reliability, and poor delivery
performance.
2. Given that Cortalo needs both suppliers, it seems sensible to first shift more
business to the true low-cost supplier and then take actions to help improve
behavior of Villa engines. Cortalo could share the ABC analysis with Villa and
show how the poor quality and delivery performance are affecting the costs
of Cortalo. Cortalo may offer to share expertise so that Villa can improve its
performance. ABC helps in strategic analysis by tracing costs to their
sources—even if those sources are outside the factory walls. It reveals
opportunities for reducing costs and improving relations with external parties
(suppliers in this case).
Problem 11.26
1. Following GAAP is fine for external financial reporting; however, for internal
reporting it may not be a good practice. By expensing order-filling costs,
management has no indication of the profitability of various customer groups
because there is no cost assigned to customers. Knowing the sources
of profitability can affect customer mix and product mix decisions. It can also
have a significant effect on deciding which customer segments to serve
(focusing strategy).
4. If Moss is to be a JIT supplier, then it should enjoy some of the benefits. One
possibility is to seek help from the buyer so that Moss can become more of a
lean manufacturer. Another possibility is to seek long-term contracts to
reduce some of the ordering costs so that smaller orders can be supplied. As
part of this, Moss might seek direct data entry to the buyer’s database. By
accessing the buyer’s production schedule, Moss can deliver the needed
parts where they are needed just in time. This also reduces Moss’s
uncertainty and facilitates its own scheduling, lowering costs.
1. Savings:
Purchasing [($30 × 1,500 part types) + ($45,000 × 15 clerks)].......... $
720,000
Inspecting ($40,000 × 12 inspectors).................................................. 480,000
Reworking ($25 × 37,500 units reworked).......................................... 937,500
Warranty [($35,000 × 13 agents) + ($15 × 5,500 units)]..................... 537,500
Total savings.................................................................................... $
2,675,000
2. The redesign reduces the number of different parts by creating products that
use interchangeable parts. This reduces the demand for purchasing activity
and, at the same time, makes it easier to implement quality-related
improvements. Supplier evaluation identifies suppliers that are willing and
able to provide defect-free parts. As the number of defect-free parts
increases, the demand for inspection, rework, and warranty activities
diminishes. This example illustrates the importance of both internal and
external linkages by connecting the internal activity, redesign, to such
activities as purchasing, inspection, rework, and warranty.
2. Traditional pricing:
Small Customer Large Customer
Prime costs................................. $14,000 $ 1,600
Overhead:
$14.30 × 2,000........................ 28,600
$14.30 × 200........................... 2,860
Total cost..................................... $42,600 $ 4,460
Units produced........................... ÷ 1,000 ÷ 100
Unit cost...................................... $ 42.60 $ 44.60
Markup (Unit cost × 0.25)........... 10.65 11.15
Current prices............................. $ 53.25 $ 55.75
3. Pool rates:
Setups: $209,000/1,045 hours = $200 per setup hour
Engineering: $151,200/630 hours = $240 per engineering hour
NC programming: $130,400/815 hours = $160 per programming hour
Machining: $100,000/50,000 hours = $2 per machine hour
Rework: $101,400/1,300 defective units = $78 per unit
Inspecting: $23,000/230 hours = $100 per inspection hour
Note: The activity capacities are computed by multiplying the average job
usage by the number of jobs.
Problem 11.28 (Continued)
Setups: (3 × 15) + (10 × 100)..................................... 1,045
Engineering: (2 × 15) + (6 × 100)............................... 630
NC programming: (1 × 15) + (8 × 100)...................... 815
Machining: (2,000 × 15) + (200 × 100)...................... 50,000
Rework: (20 × 15) + (10 × 100).................................. 1,300
Inspecting: (2 × 15) + (2 × 100)................................. 230
Small Customer Large Customer
Prime costs................................... $14,000 $1,600
Overhead:
Setups:
$200 × 3.............................. 600
$200 × 10............................ 2,000
Engineering:
$240 × 2.............................. 480
$240 × 6.............................. 1,440
NC programming:
$160 × 1.............................. 160
$160 × 8.............................. 1,280
Machining:
$2 × 2,000........................... 4,000
$2 × 200.............................. 400
Rework:
$78 × 20.............................. 1,560
$78 × 10.............................. 780
Inspecting:
$100 × 2.............................. 200
$100 × 2.............................. 200
Total cost...................................... $21,000 $7,700
Units produced............................. ÷ 1,000 ÷ 100
Unit cost........................................ $ 21.00 $77.00
Markup (Unit cost × 0.25)............ 5.25 19.25
ABC prices.................................... $ 26.25 $96.25
Problem 11.28 (Continued)
If the sales support is traced to individual products, Pawnee will discover that
the major share of this cost is being caused by the large customer. The
activity driver is the number of orders, yielding the following rate:
Sales support rate: $80,000/115 orders = $695.65* per order
*Rounded to the nearest cent.
Assignment to customers:
Small: $695.65 × 15 = $10,435*
Large: $695.65 × 100 = $69,565
*Rounded to the nearest cent.
This simply reinforces the observation that the unit cost for the large
customer is greater than the selling price. For the 10,000 units purchased by
the large customer, this would add about $6.96 of cost to each unit. This
brings the unit product cost to $83.96.
4. Current profit:
Note: Sales support requires two steps (each step’s size is 23 orders),
costing $16,000 each, for a total of $32,000.
*55 = (6 × 100) – (5 × 105) – (2 × 10)
**180 = (2 × 100) – (2 × 10)
Design B should be chosen. It meets the target profit and provides the
greatest life-cycle income. If Design B costs an additional $500,000 instead of
an additional $300,000, then it would have produced a life-cycle income of
$1,300,000—still more than the Design A income of $730,100. This illustrates
that we need to be cautious about using per-unit targets—particularly when
the life cycle is short.
4. Benefit/cost analysis:
Life-cycle profits, Design B................... $1,500,000
Life-cycle profits, initial design............ 400,000*
Increase in profits............................. $1,100,000
Additional development cost................ 300,000
Increase in benefits.......................... $ 800,000
*See Requirement 1.
Thus, $2.67* ($800,000/$300,000) of benefits will be realized for every
additional $1 spent on preproduction activities. Exploiting the linkages
between preproduction activities and other activities occurring in the later
stages of the production and consumer life-cycle stages can add significantly
to the long-run profitability of a firm.
*Rounded to the nearest cent.
Problem 11.30
Problem 11.31
2. JIT produces a more accurate unit cost because there are more costs that are
directly attributable to the product. Under JIT, costs may decrease because of
the following reasons: (1) Costs are more easily traced to the product.
Examples: The assignment of an engineer to the cell makes engineering cost
directly attributable to the cell; depreciation is also directly attributable now,
and this may explain its lower cost assignment. (2) Total quality management.
The emphasis on improving quality should reduce certain costs. Examples:
Direct materials and rework. (3) The use of multiskilled labor also may reduce
costs. Examples: Cell workers now perform inspections, move materials, do
janitorial work, and perform maintenance. (4) The use of cellular
manufacturing. Examples: No setup costs because the cell is dedicated to
one product. Less materials handling because the distance between
operations has been dramatically reduced and because suppliers may now
deliver raw materials to the cell area.
Problem 11.31 (Concluded)
3. The switch was made because the costs can be accumulated by cell and unit
costs computed by dividing cell costs by output. In other words, reorganizing
the plant layout created a structure that fits process costing.
1. Allocation ratios:
Machining Assembly
Square feet...................................... 2/3 1/3
Material moves................................ 3/5 2/5
Machine hours................................. 4/5 1/5
Allocation:
Direct overhead costs.................... $280,000 $175,000
Maintenance:
4/5 × $110,000............................ 88,000
1/5 × $110,000............................ 22,000
Materials handling:
3/5 × $90,000.............................. 54,000
2/5 × $90,000.............................. 36,000
Building and grounds:
2/3 × $150,000............................ 100,000
1/3 × $150,000............................ 50,000
Total.................................................. $ 522,000 $ 283,000
Departmental rates:
Machining:
$522,000/80,000 machine hours = $6.53* per machine hour
Assembly:
$283,000/20,000 direct labor hours = $14.15 per direct labor hour
Overhead assignment:
Eaters: ($6.53 × 1) + ($14.15 × 0.25) = $10.07*
Edgers: ($6.53 × 2) + ($14.15 × 0.50) = $20.14*
*Rounded to the nearest cent.
5. If the only trigger point is when goods are sold, then the entries would be as
follows:
Conversion Cost Control..................................... 2,160,000
Accounts Payable........................................... 1,890,000
Wages Payable................................................ 270,000
This backflush variant would operate only in a “pure” JIT setting. Cycle time
is minutes or hours, goods are shipped immediately upon completion, and
we can then argue that the manufacturing costs of the day ought to flow
directly into the cost of goods sold account.
Problem 11.34
4. Initially, the workers felt threatened by the changes, as their sense of comfort
and routine altered. Further, some were irritated by the need for retraining.
However, once the training was completed and the cell workers gained
experience, they felt a greater sense of satisfaction from the more
challenging and varied tasks. The change to JIT increased employee morale
by lessening the boredom caused by doing only one specialized task all the
time. The workers could see the product from start to finish and so could see
the result of their efforts. Moreover, they played a greater role in determining
how production ought to occur. Their sense of self-worth increased because
they had developed greater skills and were a more vital part of the whole
process.
Problem 11.34 (Concluded)
5. JIT tends to produce higher-quality products, shorter lead times,
and lower, more accurate production costs. These factors explain
the ability to increase demand. JIT adopts a philosophy of total
quality control, striving for zero
defects. This requires working closely with suppliers to ensure
that the materials of the necessary quality are delivered at the
necessary time. It also means more worker involvement in
producing a quality product. JIT encourages workers to find ways
of improving quality—to even stop production when necessary to
determine why a problem exists and how to correct it. Lead time
is reduced because of the reorganization of the manufacturing
layout.
Costs are usually reduced by JIT because of reorganization. For
example, there is no longer a need to have materials handlers.
This cost is reduced significantly. Other costs such as that of
running a central store are also reduced or eliminated. As the
per-unit cost drops, it allows the company to decrease the selling
price while increasing or maintaining the unit’s profit margin.
6. JIT can mean that more manufacturing costs are traceable to individual
products, increasing product costing accuracy. For example, the cutting
machinery was formerly in a department where it was used by several
different products, requiring machinery cost allocation. With cells, the cost of
the cutting machinery within the cell all belongs entirely to the small heaters.