Management Accounting Information for Activity and Process Decisions

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Management Accounting Information for Activity and Process Decisions

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Title: Management Accounting Information for Activity and Process Decisions


1
Management Accounting Information for Activity
and Process Decisions
  • Chapter 5

2
Evaluation of Financial Implications
  • Managers must evaluate the financial implications
    of decisions that require trade-offs between the
    costs and the benefits of different alternatives
  • Financial implications are important when
    considering decisions such as whether to
  • Redesign an entire production process or replace
    existing machines
  • Purchase services such as custodial help or to
    simply hire in-house custodians
  • Financial information about the different types
    of costs form the basis of decisions about the
    organizations activities and processes

3
Relevant Costs and Revenues
  • Whether particular costs and revenues are
    relevant for decision making depends on the
    decision context and the alternatives available
  • When choosing among different alternatives,
    managers should concentrate only on the costs and
    revenues that differ across the decision
    alternatives
  • These are the relevant cost/revenues
  • Opportunity costs by definition are relevant
    costs for any decision
  • The costs that remain the same regardless of the
    alternative chosen are not relevant for the
    decision

4
Sunk Costs are Not Relevant
  • Sunk costs often cause confusion for decision
    makers
  • Costs of resources that already have been
    committed and no current action or decision can
    change
  • Not relevant to the evaluation of alternatives
    because they cannot be influenced by any
    alternative the manager chooses

5
Replacement Of A Machine (1 of 2)
  • A Company purchased a new drilling machine for
    180,000 on September 1, 2003
  • They paid 30,000 in cash and financed the
    remaining 150,000 with a bank loan
  • The loan requires a monthly payment of 5,200 for
    the next 36 months
  • On September 27, 2003, a sales representative
    from another supplier of drilling machines
    approached the company with a newly designed
    machine that had only recently been introduced to
    the market and offered special financing
    arrangements
  • The new supplier agreed to pay 50,000 for the
    old machine, which would serve as the down
    payment required for the new machine
  • In addition, the new supplier would require
    monthly payments of 6,000 for the next 35 months

6
Replacement Of A Machine (2 of 2)
  • The new design relied on innovative computer
    chips, which would reduce the labor required to
    operate the machine
  • The company estimated that direct labor costs
    would decrease by 4,400 per month on the average
    if it purchased the new machine
  • In addition it had fewer moving parts than the
    current machine
  • The new machine would decrease maintenance costs
    by 800 per month
  • The new machine has greater reliability
  • This would allow the company to reduce materials
    scrap cost by 1,000 per month
  • Should the company dispose of the machine it just
    purchased on September 1 and buy the new machine?

7
Analysis Of Relevant Costs (1 of 3)
  • If the company buys the new machine, it will
    still be responsible for the monthly payments of
    5,200 committed to on September 1
  • Therefore, the 30,000 that it paid in cash for
    the old machine and the 5,200 it is committed to
    pay each month for the next 36 months are sunk
    costs
  • The company already has committed these
    resources, and regardless if it decides to buy
    the new machine, it cannot avoid any of these
    costs
  • None of these sunk costs are relevant to the
    decision

8
Analysis Of Relevant Costs (2 of 3)
  • What costs are relevant?
  • The 35 monthly payments of 6,000 and the down
    payment of 50,000 are relevant costs, because
    they depend on the decision
  • Labor, materials, and machine maintenance costs
    will be affected if the company acquires the new
    machine
  • The relevant expected monthly savings are
  • 4,400 in labor costs
  • 1,000 in materials costs
  • 800 in machine maintenance costs
  • The revenue of 50,000 expected on the trade-in
    of the old machine is also relevant, because the
    old machine will be disposed of only if the
    company decides to acquire the new machine

9
Analysis Of Relevant Costs (3 of 3)
  • In a comparison of the cost increases/cash
    outflows to cost savings/cash inflows
  • The down payment required for the new machine is
    matched by the expected trade-in value of the old
    machine
  • The expected savings in labor, materials, and
    machine maintenance costs each month (6,200) are
    more than the monthly lease payments for the new
    machine (6,000)
  • Thus, it is apparent that the company will be
    better off trading in the old machine and
    replacing it with the new machine

10
Difficulty of Making Correct Decision
  • The technically correct decision for the company
    on a level is to dispose of the machine and
    replace it
  • Not all managers would do so
  • They are concerned about their reputations within
    their own organization
  • Reversing a major decision made only just a month
    earlier makes the decision look like an error
  • In many circumstances, by maintaining the
    original course of action, the manager does not
    have to reveal that a better decision could have
    been made

11
Responsibility For Decisions (1 of 2)
  • If the manager does not purchase the new machine,
    then his or her behavior may be viewed as
    suboptimal
  • It ensures lower productivity or performance from
    the old machine rather than improved performance
    with the new one
  • By not making the correct decision now, the
    manager may incur the effects of a bad decision
    later
  • If the manager admits to making an error when
    purchasing the old machine, that person might
    garner more respect from colleagues for accepting
    the responsibility

12
Responsibility For Decisions (2 of 2)
  • Many decision makers have a difficult time
    distinguishing sunk cost business decisions from
    sunk cost personal decisions
  • In contrast to business decisions, the associated
    costs of previous life decisions can evoke a
    complex set of personal feelings
  • Unlike the case in the business decision, we do
    not end a friendship simply because a new friend
    materializes
  • Thus, identifying what is relevant and
    disentangling personal responses when dealing
    with business decisions are critical tasks for
    any business decision maker

13
Make-or-Buy Decisions (1 of 3)
  • As managers attempt to reduce costs and increase
    the competitiveness of their products, they face
    decisions about whether their companies should
  • Manufacture some parts and components for their
    products in-house
  • Subcontract with another company to supply these
    parts and components
  • Such make-or-buy decisions illustrate how to
    identify relevant costs and revenues

14
Make-or-Buy Decisions (2 of 3)
  • A company manufactures about 15 of the lamps
    required for its automobiles in its own plant in
    Ohio
  • The companys president would like to reduce
    costs and has asked the production manager to
    evaluate the possibility of outsourcing all the
    lamps
  • The production manager obtains firm quotes from
    several suppliers for the four types of lamps the
    company manufactures in-house
  • Standard rear lamps
  • Standard front lamps
  • Multicolored rear lamps
  • Curved side and rear lamps

15
Make-or-Buy Decisions (3 of 3)
16
Avoidable Costs (1 of 3)
  • Avoidable costs are those eliminated when a part,
    product, product line, or business segment is
    discontinued
  • If the production manager decides to outsource a
    product, the company may avoid certain production
    costs (using the std. rear lamp as an example)
  • 1,296,000 of direct material costs (36 x
    36,000)
  • 792,000 of direct labor costs (22 x 36,000)
  • 504,000 of unit-related support costs (14 x
    36,000)
  • Contraction or redeployment of resources may
    allow the company to save
  • 360,000 (10 x 36,000) of batch-related support
    costs
  • 216,000 (6 x 36,000) of product-sustaining
    support costs

17
Avoidable Costs (2 of 3)
  • To decide whether facility-sustaining support
    costs are avoidable requires further
    consideration
  • The company cannot dispose of part of the
    facility used to support the production of the
    standard rear lamp without disposing of the
    entire machine or building
  • Most facility-sustaining support costs represent
    the prorated costs of indivisible common
    facilities
  • Building space
  • Machines

18
Avoidable Costs (3 of 3)
  • It could be possible to find an alternative use
    for the part of the facility made available by
    not producing a product
  • The manager considered the possibility of
    shifting the remaining production lines to
    another facility
  • The company could save the facility-sustaining
    costs for the rental facility by terminating its
    lease there
  • Such indirect savings in facility-sustaining
    costs for the organization are relevant for the
    decision to outsource production, because they
    can arise only if the lamp is outsourced
  • The manager determined that it would be
    technically infeasible to transfer the
    manufacture of the other product lines to another
    plant

19
Summary of Financial Analysis
  • To summarize the analysis so far, if the standard
    rear lamp is outsourced, the company may avoid
    3,168,000 of manufacturing costs
  • Assuming batch-related and product sustaining
    support costs may be avoided
  • The company would spend 2,952,000 to purchase
    the parts from the low-bid supplier
  • The company could save 216,000 by outsourcing

20
Qualitative Factors
  • For most decisions such as this, several
    additional factors, which are more qualitative in
    nature, need to be considered
  • Permanence of the lower price
  • Reliability of the supplier
  • In meeting the required quality standards
  • In making deliveries on time
  • Many companies have adopted the practice of
    certifying a small set of suppliers who are
    dependable and consistent in supplying
    high-quality items as needed
  • They provide their certified suppliers with
    incentives, such as quick payments and guaranteed
    total purchase volumes

21
Facility Layout Systems (1 of 2)
  • In addition to understanding the relevant costs
    for many decisions that change the nature of
    activities and processes, managers must consider
    the entire operations process within a facility
  • There are three general types of facility
    designs
  • Process layouts
  • Product layouts
  • Cellular manufacturing
  • Regardless of the type of facility design, a
    central goal of the design process is to
    streamline operations and thus increase the
    operating income of the system

22
Facility Layout Systems (2 of 2)
  • One method that can guide this process for all
    three designs is the theory of constraints (TOC)
  • TOC maintains that operating income can be
    increased by carefully managing the bottlenecks
    in a process
  • A bottleneck is any condition that impedes or
    constrains the efficient flow of a process
  • A bottleneck can be identified by determining
    points at which excessive amounts of
    work-in-process inventories are accumulating
  • The buildup of inventories also slows the cycle
    time of production

23
Theory of Constraints (1 of 2)
  • The theory of constraints relies on the use of
    three measures
  • Throughput contribution
  • Investments
  • Operating costs
  • Throughput contribution is the difference between
    revenues and direct materials for the quantity of
    product sold
  • Investments equal the materials costs contained
    in raw materials, work-in-process, and finished
    goods inventories
  • Operating costs are all other costs, except for
    direct materials costs, that are needed to obtain
    throughput contribution

24
Theory of Constraints (2 of 2)
  • TOC emphasizes the short-run optimization of
    throughput contribution
  • Proponents of TOC view operating costs as
    difficult to alter in the short run
  • Accordingly, ABC-type analyses of activities and
    cost drivers are not conducted
  • This limits the usefulness of the theory for the
    longer run
  • In theory, however, there is no reason why TOC
    and ABC cannot be used together

25
Process Layouts
  • In a process layout, all similar equipment or
    functions are grouped together
  • Process layouts exist in organizations in which
    production of unique products is done in small
    batches
  • The product follows a serpentine path, usually in
    batches, through the factories and offices that
    create it
  • Process layouts are also characterized by high
    inventory levels
  • It is necessary to store work-in-process in each
    area while it awaits the next operation
  • Products might travel for several miles within a
    factory during the production process

26
Process Layout in a Bank (1 of 2)
  • As an example, the process associated with a bank
    loan application may occur as follows
  • The customer goes to the bank (a moving activity)
  • The bank takes the loan application from the
    customer (processing activity)
  • Loan applications are accumulated (storage
    activity)
  • and passed to a loan officer (moving activity)
  • for approval (both processing and inspection
    activity)
  • Loans that violate standard loan guidelines are
  • accumulated (storage activity) then
  • passed (moving activity) to a regional supervisor
  • for approval (processing activity)

27
Process Layout in a Bank (2 of 2)
  • The customer is contacted when a decision has
    been made (processing activity)
  • If the loan is approved, then the loan proceeds
    are deposited in the customers account
    (processing activity)
  • In most banks, work-in-process stockpiles at each
    of the processing points or stations
  • Loan applications may be piled on desk of
  • The bank teller
  • The loan officer
  • The regional supervisor

28
WIP Accumulation (1 of 3)
  • Work-in-process inventory accumulates at
    processing stations in a conventional
    organization for three reasons
  • Handling work in batches
  • At each processing station all items in the batch
    must wait while the designated employees process
    the entire batch before moving that batch to the
    next station
  • Organizations use batches, on the other hand, to
    reduce setting up, moving, and handling costs

29
WIP Accumulation (2 of 3)
  • If the rate at which each processing area handles
    work is unbalanced, work piles up at the slowest
    processing station
  • Occurs when one area is slower or has stopped
    working due to problems with equipment,
    materials, or people
  • Scheduling delays result
  • Inventory levels increase

30
WIP Accumulation (3 of 3)
  • If processing area managers are evaluated on
    their ability to meet production quotas
  • Many managers deliberately maintain large stocks
    of incoming work-in-process so that they can
    continue to work even if the processing area that
    feeds them is shut down
  • To avoid idling the next processing station and
    suffering the resulting recriminations, managers
    may store finished work they can forward to
    supply stations further down the line when their
    stations are shut down due to problems

31
Product Layouts
  • In a product layout, equipment is organized to
    accommodate the production of a specific product
  • Automobile assembly line
  • Packaging line for cereal or milk
  • Product layouts exist primarily in companies with
    high-volume production
  • The product moves along an assembly line beside
    which the parts to be added to it have been
    stored
  • Placement of equipment or processing units is
    made to reduce the distance that products must
    travel
  • Arrangements for delivery of raw materials and
    purchased parts directly to the production line
    can often be made

32
Product Layout in a Cafeteria (1 of 2)
  • Consider the work-in-process in a cafeteria
    setting
  • People pass by containers of food and take what
    they want
  • Employees organize the food preparation
    activities so that the containers are refilled
    just as they are being emptied
  • The batch-related setup costs otherwise (one
    serving at a time) would be prohibitively
    expensive

33
Product Layout in a Cafeteria (2 of 2)
  • Reducing setup costs allows for the reduction of
    batch sizes along the line
  • This reduces the level of inventory (and costs)
    in the system
  • It also improves quality while increasing
    customer satisfaction
  • The ultimate goal is to reduce setup costs to
    zero and to reduce processing time to as close to
    zero as possible, so that the system can produce
    and deliver individual products just as they are
    needed

34
Cellular Manufacturing (1 of 2)
  • Cellular manufacturing, refers to the
    organization of a plant into a number of cells
  • Within each cell all machines required to
    manufacture a group of similar products are
    arranged in close proximity to each other
  • The machines in a cellular manufacturing layout
    are usually flexible and can be adjusted easily
    or even automatically to make different products

35
Cellular Manufacturing (2 of 2)
  • The shape of a cell is often a U shape, which
    allows workers convenient access to required
    parts
  • Often when cellular manufacturing is introduced,
    the number of employees needed to produce a
    product can be reduced due to the new work design
  • The U shape also provides better visual control
    of the work flow because employees can observe
    more directly what their coworkers are doing

36
Problems with Batch Production (1 of 2)
  • It creates inventory costs
  • It also creates delays associated with storing
    and moving inventory
  • These delays increase cycle times, thereby
    reducing service to customers
  • Delays may even happen before manufacturing
    begins

37
Problems with Batch Production (2 of 2)
  • A manufacturer may require that a product be
    manufactured in some minimum batch size. If a
    customer order is less than the minimum batch
    size and if the order cannot be filled from
    existing finished goods inventory, then the
    customer must wait until enough orders have
    accumulated to meet the minimum batch size
    requirement
  • A loan application (that may take a loan officer
    only five minutes to read and approve) may have
    to wait for hours or days before it reaches the
    loan officer, because having a clerk deliver each
    new loan application when it arrives is too
    expensive

38
Inventory-Related Costs (1 of 2)
  • Demands for inventory lead to huge costs in
    organizations, including the cost of
  • Moving
  • Handling
  • Storing
  • Obsolescence or damage
  • Many organizations have found that factory
    layouts and inefficiencies that create the need
    to hold work-in-process inventory hide other
    problems leading to excessive costs of rework

39
Inventory-Related Costs (2 of 2)
  • In batch operations, workers near the end of a
    process (downstream) often find batch-size
    problems resulting from the way workers have done
    their jobs earlier in the process (upstream)
  • When work is performed continuously on one
    component at a time, however, workers downstream
    can identify an upstream problem in that
    component almost immediately and correct it
    before it leads to production of more defective
    components

40
Cost of Nonconformanceand Quality Issues
  • Cost reduction has become a significant factor in
    the management of most organizations
  • Reducing costs involves much more than simply
    finding ways to cut product design costs
  • For example, by using less expensive materials
  • The premise underlying cost reduction efforts
    today is to decrease costs while maintaining or
    improving product quality in order to be
    competitive
  • If the quality of products and services does not
    conform to quality standards, then the
    organization incurs a cost known as the cost of
    nonconformance (CONC) to quality standards

41
Quality
  • Quality usually may be viewed as hinging on two
    major factors
  • Satisfying customer expectations regarding the
    attributes and performance of the product
  • E.g., its functionality and features
  • Ensuring that the technical aspects of the
    products design and performance conform to the
    manufacturers standards
  • Whether it performs to the expected standard

42
Quality Standards
  • Global competition has led to the development of
    international quality standards
  • Company certification under these standards
    indicates to customers that management has
    committed their company to follow procedures and
    processes that will ensure the production of the
    highest-quality goods and services
  • ISO90002000 Series of Standards, developed in
    Europe, is one widely-recognized quality standard
    certification

43
ISO9000 (1 of 6)
  • In 1987, the International Organization for
    Standardization (ISO), headquartered in Geneva,
    Switzerland, developed the first ISO9000 Series
    of Standards
  • These standards were revised in 1994 and again in
    2000
  • The goal of the member nations is to develop
    globally recognized independent (third party)
    quality system verification
  • Today, over 400,000 organizations have been
    certified worldwide
  • Many types of organizations are interested in
    becoming IOS9000 registered in order to
  • Comply with external regulatory agencies,
  • Meet or exceed customer requirements, or
  • Implement a quality improvement program to remain
    competitive

44
ISO9000 (2 of 6)
  • ISO 9000 contains more than 20 standards and
    documents
  • Because of the increase in the number of
    standards, ISO 90002000 was developed
  • ISO 90002000 consists of four primary standards
    and a greatly reduced number of supporting
    documents (guidance standards, brochures,
    technical reports, technical specifications)
  • The major points in previous versions of the
    standards were integrated into the four primary
    standards

45
ISO9000 (3 of 6)
  • The four primary standards are
  • ISO 9000 Quality management systems
    Fundamentals and vocabulary
  • ISO 9001 Quality management systems
    Requirements
  • ISO 9004 Quality management systems  Guidance
    for performance improvement
  • ISO 19011 Guidelines on quality and/or
    environmental management systems auditing (To be
    published)

46
ISO9000 (4 of 6)
  • The most significant changes in the revised ISO
    9000 standards are
  • Increased focus on top management commitment
  • Emphasis on a process approach within the
    organization
  • Continual improvement
  • Increased focus on enhancing satisfaction for
    customers and other interested parties

47
ISO9000 (5 of 6)
  • The overall revisions to ISO 9001 and 9004 are
    based on eight quality management principles from
    best management practices
  • Customer focus
  • Leadership
  • Involvement of people
  • Process approach
  • System approach to management
  • Continual improvement
  • Factual approach to decision making
  • Mutually beneficial supplier relationships

48
ISO9000 (6 of 6)
The ISO 90002000 Standards apply to all kinds of
organizations in all kinds of areas
  • Manufacturing
  • Forestry
  • Electronics
  • Computing
  • Legal services
  • Financial services
  • Accounting
  • Trucking
  • Banking
  • Retailing
  • Drilling
  • Recycling
  • Aerospace
  • Construction
  • Pharmaceuticals
  • Sanitation
  • Software development
  • Consumer products
  • Transportation
  • Design
  • Tourism
  • Communications
  • Biotechnology
  • Engineering
  • Farming
  • Entertainment
  • Consulting
  • Insurance
  • and others
  • Oil and gas
  • Petrochemicals
  • Publishing
  • Shipping
  • Telecommunications
  • Health care
  • Hospitality
  • Utilities
  • Aviation
  • Food processing
  • Agriculture
  • Government
  • Education
  • Recreation
  • More information can be obtained from the
    International Organization for Standardization
    (www.iso.org)

49
Costs Of Quality Control
  • Companies have discovered that they can spend as
    much as 20 to 30 of total manufacturing costs
    on quality-related processes
  • The best-known framework for understanding
    quality costs classifies them into four
    categories
  • Prevention costs
  • Appraisal costs
  • Internal failure costs
  • External failure costs
  • Experience shows that it is much less expensive
    to prevent defects than to detect and repair them
    after they have occurred

50
Prevention Costs
  • Prevention costs are incurred to ensure that
    companies produce products according to quality
    standards
  • Quality engineering
  • Training employees in methods designed to
    maintain quality
  • Statistical process control
  • Training and certifying suppliers so that they
    can deliver defect-free parts and materials and
    better, more robust, product designs

51
Appraisal Costs
  • Appraisal costs relate to inspecting products to
    make sure they meet both internal and external
    customers requirements
  • Inspection costs of purchased parts and materials
  • Costs of quality inspection on an assembly line
  • Inspection of incoming materials
  • Maintenance of test equipment
  • Process control monitoring

52
Internal Failure Costs
  • An internal failure occurs when the manufacturing
    process detects a defective component or product
    before it is shipped to an external customer
  • Reworking defective components or products is a
    significant cost of internal failures
  • The cost of downtime in production is another
    example of internal failure
  • Engineers have estimated that the cost of defects
    rises by an order of magnitude for each stage of
    the manufacturing process that the defect goes
    undetected
  • Inserting a defective 1 electronic component
    into a subassembly leads to 10 of scrap if
    detected at the first stage, 100 at the next
    stage, and perhaps 10,000 if not detected for
    two more stages of assembly

53
External Failure Costs
  • External failures occur when customers discover a
    defect
  • All costs associated with correcting the problem
  • Repair of the product
  • Warranty costs
  • Service calls
  • Product liability recalls
  • For many companies, this is the most critical
    quality cost to avoid
  • Not only are costs required to fix the problem in
    the short run, but also customer satisfaction,
    future sales, and the reputation of the
    manufacturing organization may be in jeopardy
    over the long run

54
Cost-of-Quality Report (1 of 2)
  • This information is compiled in a cost-of-quality
    (COQ) report, developed for several reasons
  • It illustrates the financial magnitude of quality
    factors
  • Often managers are unaware of the enormous impact
    that rework has on their costs
  • Cost-of-quality information helps managers set
    priorities for the quality issues and problems
    they should address
  • For example, one trend that managers do not want
    to see is a very high percentage of quality costs
    coming from external failure of a product
  • External quality problems are expensive to fix
    and can greatly harm the reputation of the
    product or organization producing the product

55
Cost-of-Quality Report (2 of 2)
  • The cost of quality report allows managers to see
    the big picture of quality issues
  • It allows them to try to find the root causes of
    their quality problems
  • The problem at its root will have positive ripple
    effects throughout the organization, as so many
    quality issues are interrelated

56
Just-in-Time Manufacturing
  • Just-in-time (JIT) manufacturing is a
    comprehensive and effective manufacturing system
    that integrates many of the ideas discussed in
    this chapter
  • Just-in-time production requires making a product
    or service only when the customer, internal or
    external, requires it
  • It uses a product layout with a continuous flow
  • No delays once production starts
  • There must be a substantial reduction in setup
    costs in order to eliminate the need to produce
    in batches
  • Processing systems must be reliable

57
Implications Of JIT Manufacturing (1 of 6)
  • Just-in-time manufacturing is simple in theory
    but hard to achieve in practice
  • Some organizations hesitate to implement JIT
  • With no work-in-process inventory a problem
    anywhere in the system can stop all production
  • Organizations that use just-in-time manufacturing
    must eliminate all sources of failure in the
    system
  • The production process must be redesigned so that
    it is not prohibitively expensive to process one
    or a small number of items at a time
  • This usually means reducing the distance over
    which work in process has to travel and using
    very adaptable people and equipment that can
    handle all types of jobs

58
Implications Of JIT Manufacturing (2 of 6)
  • At the core of the JIT process is a highly
    trained workforce whose task is to carry out
    activities using the highest standards of quality
  • When an employee discovers a problem with a
    component he or she has received, it is the
    responsibility of that employee to call immediate
    attention to the problem so that it can be
    corrected
  • Suppliers must be able to produce and deliver
    defect-free materials or components just when
    they are required
  • In many instances, companies hold a competition
    between suppliers of the same components to see
    who can deliver the best quality
  • At the end of a performance period, the supplier
    who performs the best will obtain a long-term
    contract
  • Preventative maintenance is also employed so that
    equipment failure is a rare event

59
Implications Of JIT Manufacturing (3 of 6)
  • Just-in-time manufacturing has two major
    implications for management accounting
  • First, management accounting must support the
    move to JIT manufacturing by monitoring,
    identifying, and communicating to decision makers
    the sources of delay, error, and waste in the
    system
  • Second, the clerical process of management
    accounting is simplified by JIT manufacturing,
    due to the smaller inventory to monitor and report

60
Implications Of JIT Manufacturing (4 of 6)
  • Important measures of a JIT systems reliability
    include the following benchmarks of manufacturing
    cycle effectiveness
  • Defect rates
  • Cycle times
  • Percent of time that deliveries are on time
  • Order accuracy
  • Actual production as a percent of planned
    production
  • Actual machine time available compared with
    planned machine time available
  • Conventional labor and machine productivity
    ratios are inconsistent with the just-in-time
    production philosophy

61
Implications Of JIT Manufacturing (5 of 6)
  • Just-in-time manufacturing has been a benefit to
    many organizations
  • Those interested in implementing this system need
    to remember several things
  • Any significant management innovation, such as
    ABC or JIT, requires a major cultural change for
    an organization
  • JIT also can alter the pace of work and the
    overall work discipline of the organization
  • It can cause structural changes in such areas as
    the arrangement of shop floors

62
Implications Of JIT Manufacturing (6 of 6)
  • Because the central ideas behind JIT are the
    streamlining of operations and the reduction of
    waste, many people inside companies are
    ill-prepared for the change
  • Because JIT relies on teamwork, often individuals
    have to subordinate their own interests to those
    of the team
  • Some employees find this difficult, especially if
    they have come from a work environment where they
    worked on a single component in relative
    isolation, or if their personalities are not team
    oriented

63
If you have any comments or suggestions
concerning this PowerPoint presentation, please
contactTerry M. Lease(terry.lease_at_sonoma.edu)S
onoma State University
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