Title: Management Accounting Information for Activity and Process Decisions
1Management Accounting Information for Activity
and Process Decisions
2Evaluation 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
3Relevant 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
4Sunk 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
5Replacement 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
6Replacement 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?
7Analysis 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
8Analysis 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
9Analysis 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
10Difficulty 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
11Responsibility 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
12Responsibility 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
13Make-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
14Make-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
15Make-or-Buy Decisions (3 of 3)
16Avoidable 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
17Avoidable 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
18Avoidable 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
19Summary 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
20Qualitative 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
21Facility 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
22Facility 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
23Theory 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
24Theory 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
25Process 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
26Process 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)
27Process 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
28WIP 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
29WIP 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
30WIP 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
31Product 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
32Product 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
33Product 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
34Cellular 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
35Cellular 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
36Problems 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
37Problems 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
38Inventory-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
39Inventory-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
40Cost 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
41Quality
- 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
42Quality 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
43ISO9000 (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
44ISO9000 (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
45ISO9000 (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)
46ISO9000 (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
47ISO9000 (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
48ISO9000 (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)
49Costs 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
50Prevention 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
51Appraisal 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
52Internal 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
53External 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
54Cost-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
55Cost-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
56Just-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
57Implications 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
58Implications 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
59Implications 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
60Implications 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
61Implications 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
62Implications 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
63If you have any comments or suggestions
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