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ABC is a costing approach that assigns resource costs to cost objects such as
products, services, or customers based on activities performed for the cost
objects. The premise of this costing approach is that a firm’s products or
services are the results of activities and activities use resources which incur
costs. Costs of resources are assigned to activities based on the activities
that use or consume resources (resource consumption drivers), and costs of
activities are assigned to cost objects based on the activities performed for
the cost objects (activity consumption drivers). ABC recognizes the causal
or direct relationships between resource costs, cost drivers, activities, and
cost objects in assigning costs to activities and then to cost objects.
Definition :-
Activity- An activity is a specific deed, action, or work performed. An activity can
be a single action or an aggregation of several actions.
Resource- It is an economic element needed or consumed in performing
activities.
Cost Driver- It is a factor that causes or relates to a change in the cost of an
activity.
STEPS IN DESIGNING ABC SYSTEM
• STEP-I
Identify resource costs and activities
STEP-II
Assign resource costs to activities
STEP-III
Assign activity costs to cost objects
VALUE ANALYSIS & VALUE ENGINEERING
Def:-
• A systematic analysis and evaluation of the techniques and functions
in the various spheres of an organisation with a view to exploring
channels of performance improvement so that the value in a particular
product can be bettered.
• According to US Department of Defence --
An organised effort directed at analysing the function of systems,
equipments, facilities, services and supplies for the purpose of
achieving essential functions at the lowest life cycle cost consistent
with required performance, reliability, maintainability,
interchangeability, product quality & safety.
• As defined by Raven –
An analytical technique, designed to examine all the facets and costs
of a product, in order to determine whether or not any item of cost can
be reduced or eliminated, while retaining all functional, performance
and quality requirements.
The important objective of Value Analysis and engineering is to reduce
costs without loss of quality or function. It is a team work involving
designers, engineers, purchase managers and accountants.
The economic value of a product is the combination of Use value, Cost value,
Esteem value and Exchange value.
• Use Value : It refers to the characteristics and features which make the
product useful for which it is intended.
• Esteem Value :- It makes an ownership of an objective desirable and
make it attractive which would induce customer to buy.
• Cost Value:- It is the total cost i.e. material, labour and overheads required
to produce an item in case of manufactured items and the cost of purchase
in case if obtained from outside.
• Exchange Value :- It refers to properties of an object that makes it
possible to procure other items by trading.
Distinction between Value Engineering & Value Analysis
Value Analysis aims at reducing cost by economising expenditure and
increasing productivity and it probes into economic attributes of value and
through continuous process of planned action to improve performance.
Value Engineering concentrates mainly on direct costs. Value Engineering may be
applied in the production stage i.e. in the design & development stage whereas
value analysis applied to existing products already being marketed.
Benefits of Value Analysis:-
• It enables to identify and pinpoint areas that need attention and improvement.
• It ensures and maintains the desired quality products and suggest the
manufacture of the most suitable products.
• It provides a method of generating ideas and alternatives for possible solutions
to a concern.
• It is an effective tool for cost reduction.
• It concentrates on customer satisfaction which lead to profitability of the
organisation.
• By a continuing search for improvement, it creates an atmosphere for increase
of efficiency.
• It makes possible optimum use of all resources.
• It promotes innovation and creativity.
• It suggests improved methods of production and use of latest manufacturing
techniques which have the effect of raising productivity & minimising cost.
• The process is sufficiently flexible. It can be repeated, explained and amended
in the light of new or different information or challenge.
CASE STUDY: VALUE ENGINEERING &
TARGET COSTING
• Digital Electronics is the market leader in digital cameras. It’s video
camera brand ‘Dynashot’ was launched in the market which although
received an overwhelming response but stressed it’s bottom – line
considerably. The projected cost structure has following break –up per
unit.
Particulars Cost Rs.
Manufacturing Cost
Direct Material (bought in parts) 31200
Direct Labour 8000
Direct Machine Costs 1600
Ordering & Receiving 640
Quality Assurance 4800
Rework 1200
Engineering & Design 800
48240
Non-Manufacturing Costs
Marketing 3200
Distribution 2400
After-sales service and warranty costs 2160
7760
Total Cost 56000
The launching price of the product was Rs.64000, however the company’s
policy is to charge 30% profit on the selling price across it’s entire product
range. In view of this the company can’t increase it’s selling price due to
stiff competition in the market. The only alternative to company is to
reduce the cost.
In response to the need to reduce the projected cost, the project team starts
by purchasing video cameras manufactured by it’s close competitors &
undertaking a tear-down analysis. This process involves dismantling the
cameras to provide insights into potential design improvements for the
new camera that will be launched. Value engineering was undertaken with
the project team working closely with design engineers. The objective is to
identify new designs that will accomplish the same functions at a lower
cost and also to eliminate any functions that are deemed to be
unnecessary. This process results
in a simplified design, the reduction in the number of parts and
replacement of some customised parts with standard parts. The analysis
resulted in a significant reduction in the projected direct materials, labour
and rework costs.
Next the team engaged in functional analysis. They identified the different
elements functions and attributes of the camera and potential customers
were interviewed to ascertain the values that they place on each of the
functions. This process indicated several functions that have been
included in the prototype are not valued by the customers. The team
therefore decided to eliminate these functions. This resulted into cost
savings in the areas of material cost & labour cost.
The next focus was redesigning the production & support processes. It was
decided to redesign the ordering and receiving process by reducing the
number of suppliers and working closely with a smaller number of
suppliers. The contractual agreements were made with the suppliers with
predetermined production schedule and in return they will inspect the
shipments and guarantee quality prior to delivery. In addition, the
marketing, distribution and customer after sales service relating to the
product and process improvements were made that resulted in further
reduction in costs attributable to video camera.
The whole exercise of Value Engineering & Target Costing resulted into
new projections as follows.
• Projected lifetime sales volume 300,000 units
• Target selling price Rs.64000
• Target profit-margin (30% of selling price) Rs.19200
• Target Cost Rs.44800
The simplified product design enabled the assembly time to be reduced thus
resulting in direct labour costs reducing by 20%. It was not possible to reduce
direct machining costs as these are committed costs and moreover fixed in
nature.
There were 80 separate parts earlier. The estimated number of orders placed for
each part throughout the product’s life cycle is 150 and predicted cost per order
for the order and receiving activity is Rs16000. Therefore the estimated lifetime
costs are (80*150*16000 = 19.2 cr) giving a unit cost of Rs.640.
The simplified design and the parts standardisation arising from the functional
analysis and the value engineering activities, enabled the number of parts to be
reduced to 40.
The redesign of the ordering and receiving process enabled the number of orders
and ordering cost to be reduced from i.e.from150 orders to 100 orders and ordering
cost from Rs 16000 to Rs.12000. Thus lifetime cost of
(40parts*100orders*Rs12000 = Rs.4.8cr) giving revised cost of Rs.160 per unit.
Quality Assurance involves inspecting & testing the cameras. Previously the
projected cost was Rs 4800 (12hrs @ Rs400per hr) but the simplified
design resulted in revised cost Rs.4000 (10hrs @ Rs400 per hr).
It is estimated that 10% of output requires rework. Thus in a lifetime 30000
cameras need to be reworked. This cost is charged to entire output. The
actual cost of reworking for the defective10% output is estimated to be
Rs.12000 per unit which will be distributed @ Rs.1200 per unit on each
camera. Due to simplified design rework rate reduced to 5% and also
rework cost to Rs.9600 per defective unit. Total lifetime cost thus would be
(15000* Rs9600 = Rs.14,40,00000) giving unit cost of rework as Rs.480 per
unit.
The predicted total lifetime engineering & design costs are Rs.24,00,00,000
giving unit cost of Rs.800. The simplified design & reuced no. of parts
enables the lifetime cost to be reduced by 20% which brings unit cost down
to Rs.640.The planned process improvements have also enabled the
predicted marketing, distribution and after-sales service costs to be
reduced. In addition, the simplified product design and the use of fewer
parts has contributed to the reduction to the after-sales warranty costs.
With the value engineering & target costing exercise the proposed cost structure will
be as follows.
Particulars Before After
Manufacturing Cost Rs. Rs. Rs.
Rs.
Direct Material 31200 26000
Direct Labour 8000 6400
Direct Machining Costs 1600 1600
Ordering & Receiving 640 160
Quality Assurance 4800 4000
Rework 1200 480
Engineering & Design 800 640
48240 39280
Non-Manufacturing Costs
Marketing 3200 2000
Distribution 2400 1600
After sales & warranty 2160 1520
7760 5120
Total Cost 56000 44400
The Value engineering has brought down the aggregate cost by
Rs.400
as compared to the target cost of Rs.44800.
WASTE MANAGEMENT
Following aspects are covered under waste management.
• Waste Control
• Scrap Control
• Spoilage Control
• Control of Defectives
Waste Control :- Waste is a material loss during production or storage due to
evaporation, chemical reaction, unrecoverable residue, shrinkage etc.
Wastage may be visible at times or invisible. It may be a normal waste
incidental to manufacturing activities or abnormal waste which is in excess
over the normal and invites a corrective action. Control on waste can be
exercised achieved in the following aspects.
• Quantity Control :- It involves maintenance of detailed records of
quantities with an object to detect shrinkage, breakage, loss etc.
Establishment of output ratios are much helpful in framing strategies for
waste control. Normal allowances of waste can be fixed with technical
assessment and past experience along with due consideration to the
special features of material and processes. A systematic procedure for
feedback of achievements against standards laid down for wastage
will improve the quality control aspect of the production. Study of the
causes of abnormal wastage helps in fixing the responsibility. Better
material handling systems will also help control of waste.
• Quality Control:- Wastage may also occur from loss of control on process
or poor quality of material. Fixing the responsibilities for purchase, stores,
production and maintenance departments to ensure achievement on
standards will provide a strategic advantage.
Scrap Control :- Scrap control is the residue material that has a recovery value.
It is incidental residue from the materials used in manufacturing operations
which is recoverable and measurable without processing. For control purpose
scrap may be classified into the following:
Legitimate Scrap:- Predetermined or anticipated in advance due to experience
in manufacturing operations.
Administrative Scrap:- Results from administrative decision e.g. change in
design or withdrawal from saleable lots or for some other reasons.
Defective Scrap:- Resulting from poor quality of raw material, negligient
handling of material etc.
Scrap can be controlled in the following ways: