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Managerial Accounting

and Cost Concepts


Chapter 2

© 2012 McGraw-Hill Education (Asia)


Work of Management

Planning
Directing and
Motivating

Controlling

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 2
Planning

Identify
alternatives.

Select alternative that does


the best job of furthering
organization’s objectives.

Develop budgets to guide


progress toward the
selected alternative.
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 3
Directing and Motivating

Directing and motivating involves managing


day-to-day activities to keep the organization running
smoothly.
 Employee work assignments.
 Routine problem solving.
 Conflict resolution.
 Effective communications.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 4
Controlling
The control function ensures
that plans are being followed.

Feedback in the form of performance reports


that compare actual results with the budget
are an essential part of the control function.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 5
Planning and Control Cycle
Formulating long-
Begin
and short-term plans
(Planning)

Comparing actual
Implementing
to planned Decision plans (Directing
performance Making and Motivating)
(Controlling)

Measuring
performance
(Controlling)

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 6
Learning Objective 1

Identify the major


differences and similarities
between financial and
managerial accounting.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 7
Comparison of Financial and Managerial
Accounting
Financial Accounting Managerial Accounting
1. Users External persons who Managers who plan for
make financial decisions and control an organization
2. Time focus Historical perspective Future emphasis
3. Verifiability Emphasis on Emphasis on relevance
versus relevance verifiability for planning and control
4. Precision versus Emphasis on Emphasis on
timeliness precision timeliness
5. Subject Primary focus is on Focuses on segments
the whole organization of an organization
6. GAAP Must follow GAAP Need not follow GAAP
and prescribed formats or any prescribed format
7. Requirement Mandatory for Not
external reports Mandatory

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 8
Learning Objective 2

Identify and give examples


of each of the three basic
manufacturing cost
categories.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 9
Manufacturing Costs

Direct Direct Manufacturing


Materials Labor Overhead

The Product

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 10
Direct Materials

Raw materials that become an integral


part of the product and that can be
conveniently traced directly to it.

Example: A radio installed in an automobile

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 11
Direct Labor

Those labor costs that can be easily


traced to individual units of product.

Example: Wages paid to automobile assembly workers

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 12
Manufacturing Overhead
Manufacturing costs that cannot be traced
directly to specific units produced.

Examples: Indirect materials and indirect labor

Materials used to support Wages paid to employees


the production process. who are not directly
involved in production
Examples: lubricants and work.
cleaning supplies used in the Examples: maintenance
automobile assembly plant. workers, janitors and
security guards.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 13
Nonmanufacturing Costs

Selling Administrative
Costs Costs

Costs necessary to All executive,


secure the order and organizational, and
deliver the product. clerical costs.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 14
Learning Objective 3

Distinguish between
product costs and period
costs and give examples
of each.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 15
Product Costs Versus Period Costs

Product costs include Period costs include all


direct materials, direct selling costs and
labor, and administrative costs.
manufacturing
overhead.

Inventory Cost of Good Sold Expense

Sale

Balance Income Income


Sheet Statement Statement
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 16
Quick Check 

Which of the following costs would be considered a


period rather than a product cost in a manufacturing
company?
A. Manufacturing equipment depreciation.
B. Property taxes on corporate headquarters.
C. Direct materials costs.
D. Electrical costs to light the production
facility.
E. Sales commissions.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 17
Quick Check 

Which of the following costs would be considered a


period rather than a product cost in a manufacturing
company?
A. Manufacturing equipment depreciation.
B. Property taxes on corporate headquarters.
C. Direct materials costs.
D. Electrical costs to light the production
facility.
E. Sales commissions.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 18
Classifications of Costs

Manufacturing costs are often


classified as follows:
Direct Direct Manufacturing
Material Labor Overhead

Prime Conversion
Cost Cost

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 19
Comparing Merchandising and
Manufacturing Companies
Merchandisers . . . Manufacturers . . .
 Buy finished goods.  Buy raw materials.
 Sell finished goods.  Produce and sell
finished goods.

MegaLoMart

McGraw-Hill Education (Asia)


McGraw-Hill/Irwin Garrison, Noreen, Brewer, Cheng & Yuen
Balance Sheet

Merchandiser Manufacturer
Current assets Current Assets
 Cash  Cash
 Receivables  Receivables
 Merchandise Inventory  Inventories
• Raw Materials
• Work in Process
• Finished Goods

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 21
Balance Sheet

Merchandiser Manufacturer
Current assets Current Assets
 Cash  Cash
Materials waiting to
 Receivables  Receivables
be processed.
 Merchandise Inventory  Inventories
Partially complete
products – some • Raw Materials
material, labor, or • Work in Process
overhead has been • Finished Goods
added.
Completed products
awaiting sale.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 22
Learning Objective 4

Prepare an income
statement including
calculation of the cost of
goods sold.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 23
The Income Statement
Cost of goods sold for manufacturers differs only
slightly from cost of goods sold for merchandisers.

Merchandising Company Manufacturing Company


Cost of goods sold: Cost of goods sold:
Beg. merchandise Beg. finished
inventory $ 14,200 goods inv. $ 14,200
+ Purchases 234,150 + Cost of goods
Goods available manufactured 234,150
for sale $ 248,350 Goods available
- Ending for sale $ 248,350
merchandise - Ending
inventory (12,100) finished goods
= Cost of goods inventory (12,100)
sold $ 236,250 = Cost of goods
sold $ 236,250

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 24
Basic Equation for Inventory Accounts

Withdrawals
Beginning Additions Ending
balance + to inventory = balance + from
inventory

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 25
Quick Check 

If your inventory balance at the beginning of the


month was $1,000, you bought $100 during the
month, and sold $300 during the month, what would
be the balance at the end of the month?
A. $1,000.
B. $ 800.
C. $1,200.
D. $ 200.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 26
Quick Check 

If your inventory balance at the beginning of the


month was $1,000, you bought $100 during the
month, and sold $300 during the month, what would
be the balance at the end of the month?
A. $1,000.
B. $ 800.
$1,000 + $100 = $1,100
C. $1,200. $1,100 - $300 = $800
D. $ 200.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 27
Learning Objective 5

Prepare a schedule of cost


of goods manufactured.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 28
Schedule of Cost of Goods Manufactured

Calculates the cost of raw


material, direct labor, and
manufacturing overhead
used in production.

Calculates the manufacturing


costs associated with goods
that were finished during the
period.
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 29
Product Cost Flows

Manufacturing Work
Raw Materials Costs In Process

Beginning raw Direct materials


materials inventory
+ Raw materials
purchased
= Raw materials
available for use
in production
– Ending raw materials
inventory
= Raw materials used
As items are removed from raw
in production materials inventory and placed into
the production process, they are
called direct materials.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 30
Product Cost Flows

Manufacturing Work
Raw Materials Costs In Process
Conversion
Beginning raw Direct materials
materials inventory + Direct labor
costs are costs
+ Raw materials + Mfg. overhead incurred to
purchased = Total manufacturing convert the
= Raw materials costs
direct material
available for use
in production into a finished
– Ending raw materials product.
inventory
= Raw materials used
in production

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 31
Product Cost Flows

Manufacturing Work
Raw Materials Costs In Process

Beginning raw Direct materials Beginning work in


materials inventory + Direct labor process inventory
+ Raw materials + Mfg. overhead + Total manufacturing
purchased = Total manufacturing costs
= Raw materials costs = Total work in
available for use process for the
in production period
– Ending raw materials
inventory All manufacturing costs incurred
= Raw materials used during the period are added to the
in production
beginning balance of work in
process.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 32
Product Cost Flows

Manufacturing Work
Raw Materials Costs In Process

Beginning raw Direct materials Beginning work in


materials inventory + Direct labor process inventory
+ Raw materials + Mfg. overhead + Total manufacturing
purchased = Total manufacturing costs
= Raw materials costs = Total work in
available for use process for the
in production period
– Ending raw materials – Ending work in
inventory
Costs associated with the goods that process inventory
= Raw materials used = Cost of goods
areincompleted
production
during the period are manufactured
transferred to finished goods
inventory.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 33
Product Cost Flows

Work
In Process Finished Goods

Beginning work in Beginning finished


process inventory goods inventory
+ Manufacturing costs + Cost of goods
for the period manufactured
= Total work in process = Cost of goods
for the period available for sale
– Ending work in - Ending finished
process inventory goods inventory
= Cost of goods Cost of goods
manufactured sold

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 34
Manufacturing Cost Flows
Balance Sheet Income
Costs Inventories Statement
Expenses
Material Purchases Raw Materials

Direct Labor Work in


Process
Manufacturing
Overhead Cost of
Finished
Goods
Goods
Sold

Selling and Period Costs Selling and


Administrative Administrative
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 35
Quick Check 

Beginning raw materials inventory was $32,000.


During the month, $276,000 of raw material was
purchased. A count at the end of the month revealed
that $28,000 of raw material was still present. What
is the cost of direct material used?
A. $276,000
B. $272,000
C. $280,000
D. $ 2,000

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 36
Quick Check 

Beginning raw materials inventory was $32,000.


During the month, $276,000 of raw material was
purchased. A count at the end of the month revealed
that $28,000 of raw material was still present. What
is the cost of direct material
Beg.used?
raw materials $ 32,000
+ Raw materials
A. $276,000 purchased 276,000
B. $272,000 = Raw materials available
for use in production $ 308,000
C. $280,000 – Ending raw materials
D. $ 2,000 = Rawinventory
materials used
28,000

in production $ 280,000

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 37
Quick Check 

Direct materials used in production totaled


$280,000. Direct labor was $375,000 and
factory overhead was $180,000. What were total
manufacturing costs incurred for the month?
A. $555,000
B. $835,000
C. $655,000
D. Cannot be determined.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 38
Quick Check 

Direct materials used in production totaled


$280,000. Direct labor was $375,000 and
factory overhead was $180,000. What were total
manufacturing costs incurred for the month?
A. $555,000
B. $835,000
C. $655,000 Direct Materials $ 280,000
D. Cannot be+determined.
Direct Labor 375,000
+ Mfg. Overhead 180,000
= Mfg. Costs Incurred
for the Month $ 835,000

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 39
Quick Check 

Beginning work in process was $125,000.


Manufacturing costs incurred for the month
were $835,000. There were $200,000 of
partially finished goods remaining in work in
process inventory at the end of the month.
What was the cost of goods manufactured
during the month?
A. $1,160,000
B. $ 910,000
C. $ 760,000
D. Cannot be determined.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 40
Quick Check 

Beginning work in process was $125,000.


Manufacturing costs incurred for the month
were $835,000. There were $200,000 of
partially finished goods remaining in work in
process inventory at the end of the
Beginning workmonth.
in
process inventory $ 125,000
What was the cost of goods manufactured
+ Mfg. costs incurred
during the month? for the period 835,000

A. $1,160,000 = Total work in process


during the period $ 960,000
B. $ 910,000 – Ending work in
C. $ 760,000 = Costprocess inventory
of goods
200,000

D. Cannot be determined.
manufactured $ 760,000

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 41
Quick Check 

Beginning finished goods inventory was


$130,000. The cost of goods manufactured for
the month was $760,000. And the ending
finished goods inventory was $150,000. What
was the cost of goods sold for the month?
A. $ 20,000.
B. $740,000.
C. $780,000.
D. $760,000.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 42
Quick Check 

Beginning finished goods inventory was


$130,000. The cost of goods manufactured for
the month was $760,000. And the ending
finished goods inventory was $150,000. What
was the cost of goods sold for the month?
A. $ 20,000.
B. $740,000.
$130,000 + $760,000 = $890,000
C. $780,000.
$890,000 - $150,000 = $740,000
D. $760,000.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 43
Learning Objective 6

Understand the
differences between
variable costs and fixed
costs.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 44
Cost Classifications for Predicting Cost
Behavior

How a cost will react to


changes in the level of
activity within the
relevant range.
 Total variable costs
change when activity
changes.
 Total fixed costs remain
unchanged when activity
changes.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 45
Variable Cost

Your total texting bill is based on how


many texts you send.
Total Texting Bill

Number of Texts Sent

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 46
Variable Cost Per Unit

The cost per text sent is constant at


5 cents per text.

Cost Per Text Sent


Number of Texts Sent

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 47
Fixed Cost
Your monthly contract fee for your cell phone is fixed
for the number of monthly minutes in your contract.
The monthly contract fee does not change based on
the number of calls you make.
Monthly Cell Phone
Contract Fee

Number of Minutes Used


Within Monthly Plan
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 48
Fixed Cost Per Unit

Within the monthly contract allotment, the average


fixed cost per cell phone call made decreases as
more calls are made.

Monthly Cell Phone


Contract Fee
Number of Minutes Used
Within Monthly Plan
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 49
Cost Classifications for Predicting Cost
Behavior

Behavior of Cost (within the relevant range)


Cost In Total Per Unit

Variable Total variable cost changes Variable cost per unit remains
as activity level changes. the same over wide ranges
of activity.
Fixed Total fixed cost remains Average fixed cost per unit goes
the same even when the down as activity level goes up.
activity level changes.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 50
Quick Check 

Which of the following costs would be variable


with respect to the number of cones sold at a
Baskins & Robbins shop? (There may be more
than one correct answer.)
A. The cost of lighting the store.
B. The wages of the store manager.
C. The cost of ice cream.
D. The cost of napkins for customers.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 51
Quick Check 

Which of the following costs would be variable


with respect to the number of cones sold at a
Baskins & Robbins shop? (There may be more
than one correct answer.)
A. The cost of lighting the store.
B. The wages of the store manager.
C. The cost of ice cream.
D. The cost of napkins for customers.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 52
Learning Objective 7

Understand the
differences between direct
and indirect costs.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 53
Assigning Costs to Cost Objects
Direct costs Indirect costs
 Costs that can be  Costs that cannot be
easily and easily and
conveniently traced conveniently traced
to a unit of product to a unit of product
or other cost object. or other cost object.
 Examples: direct  Example:
material and direct manufacturing
labor overhead

McGraw-Hill Education (Asia)


McGraw-Hill/Irwin Garrison, Noreen, Brewer, Cheng & Yuen
Learning Objective 8
Define and give examples
of cost classifications used
in making decisions:
differential costs,
opportunity costs, and
sunk costs.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 55
Cost Classifications for Decision Making

 Every decision involves a choice


between at least two
alternatives.

 Only those costs and benefits


that differ between alternatives
are relevant in a decision. All
other costs and benefits can
and should be ignored.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 56
Differential Cost and Revenue

Costs and revenues that differ


among alternatives.
Example: You have a job paying $1,500 per month in
your hometown. You have a job offer in a neighboring
city that pays $2,000 per month. The commuting cost
to the city is $300 per month.

Differential revenue is: Differential cost is:


$2,000 – $1,500 = $500 $300

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 57
Opportunity Cost
The potential benefit that is given
up when one alternative is selected
over another.

Example: If you were


not attending college,
you could be earning
$15,000 per year.
Your opportunity cost
of attending college for
one year is $15,000.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 58
Sunk Costs

Sunk costs have already been incurred and cannot


be changed now or in the future. These costs
should be ignored when making decisions.

Example: You bought an automobile that cost


$10,000 two years ago. The $10,000 cost is sunk
because whether you drive it, park it, trade it, or sell
it, you cannot change the $10,000 cost.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 59
Quick Check 

Suppose you are trying to decide whether to


drive or take the train to Kuala Lumpur to attend
a concert. You have ample cash to do either, but
you don’t want to waste money needlessly. Is
the cost of the train ticket relevant in this
decision? In other words, should the cost of the
train ticket affect the decision of whether you
drive or take the train to Kuala Lumpur?
A. Yes, the cost of the train ticket is relevant.
B. No, the cost of the train ticket is not relevant.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 60
Quick Check 

Suppose you are trying to decide whether to


drive or take the train to Kuala Lumpur to attend
a concert. You have ample cash to do either, but
you don’t want to waste money needlessly. Is
the cost of the train ticket relevant in this
decision? In other words, should the cost of the
train ticket affect the decision of whether you
drive or take the train to Kuala Lumpur?
A. Yes, the cost of the train ticket is relevant.
B. No, the cost of the train ticket is not relevant.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 61
Quick Check 

Suppose you are trying to decide whether to


drive or take the train to Kuala Lumpur to attend
a concert. You have ample cash to do either, but
you don’t want to waste money needlessly. Is
the annual cost of licensing your car relevant in
this decision?
A. Yes, the licensing cost is relevant.
B. No, the licensing cost is not relevant.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 62
Quick Check 

Suppose you are trying to decide whether to


drive or take the train to Kuala Lumpur to attend
a concert. You have ample cash to do either, but
you don’t want to waste money needlessly. Is
the annual cost of licensing your car relevant in
this decision?
A. Yes, the licensing cost is relevant.
B. No, the licensing cost is not relevant.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 63
Quick Check 

Suppose that your car could be sold now for


$5,000. Is this a sunk cost?
A. Yes, it is a sunk cost.
B. No, it is not a sunk cost.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 64
Quick Check 

Suppose that your car could be sold now for


$5,000. Is this a sunk cost?
A. Yes, it is a sunk cost.
B. No, it is not a sunk cost.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 65
Summary of the Types of Cost
Classifications

Financial Predicting Cost


Reporting Behavior

Assigning Costs Making Business


to Cost Objects Decisions

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 66
Further Classification of Labor Costs

Appendix 2A

© 2012 McGraw-Hill Education (Asia)


Learning Objective 9

(Appendix 2A)
Properly account for labor
costs associated with idle
time, overtime, and fringe
benefits.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 68
Idle Time

Machine Material
Breakdowns Shortages

Power
Failures

The labor costs incurred


during idle time are ordinarily
treated as manufacturing
overhead.
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 69
Overtime
The overtime premiums for all factory workers are
usually considered to be part of manufacturing
overhead.

What if a company consistently has overtime ?


Can the overtime costs be part of labor expenses?

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 70
Labor Fringe Benefits

Fringe benefits include employer paid


costs for insurance programs, retirement
plans, supplemental unemployment
programs, Social Security, Medicare,
workers’ compensation, and
unemployment taxes.

Some companies Other companies treat


include all of these fringe benefit
costs in expenses of direct
manufacturing laborers as additional
overhead. direct labor costs.
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 71
Cost of Quality

Appendix 2B

© 2012 McGraw-Hill Education (Asia)


Learning Objective 10

(Appendix 2B)
Identify the four types of
quality costs and explain
how they interact.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 73
Quality of Conformance

When the overwhelming majority of products


produced conform to design specifications
and are free from defects.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 74
Prevention and Appraisal Costs
Support activities
Prevention whose purpose is to
Costs reduce the number of
defects

Incurred to identify
defective products
Appraisal Costs before the products are
shipped to customers

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 75
Internal and External Failure Costs

Incurred as a result of
Internal Failure
identifying defects
Costs before they are shipped

Incurred as a result of
External Failure defective products
Costs being delivered to
customers

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 76
Examples of Quality Costs

Appraisal Costs
Prevention Costs
• Testing and inspecting
• Quality training
incoming materials
• Quality circles
• Final product testing
• Statistical process
• Depreciation of testing
control activities
equipment

External Failure Costs


Internal Failure Costs
• Cost of field servicing and
• Scrap
handling complaints
• Spoilage
• Warranty repairs
• Rework
• Lost sales

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 77
Distribution of Quality Costs

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 78
Learning Objective 11

(Appendix 2B)
Prepare and interpret a
quality cost report.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 79
Quality Cost Report
For Years 1 and 2
Year 2 Year 1
Amount Percent* Amount Percent*
Prevention costs:
Systems development $ 400,000 0.80% $ 270,000 0.54%
Quality training 210,000 0.42% 130,000 0.26%
Supervision of prevention activities 70,000 0.14% 40,000 0.08%
Quality improvement 320,000 0.64% 210,000 0.42%
Total prevention cost 1,000,000 2.00% 650,000 1.30%

Appraisal costs:
Inspection 600,000 1.20% 560,000 1.12%
Quality cost
Reliability testing
Supervision of testing and inspection
580,000
120,000
1.16%
0.24%
420,000
80,000
0.84%
0.16%
reports provide
Depreciation of test equipment 200,000 0.40% 140,000 0.28% an estimate of
Total appraisal cost 1,500,000 3.00% 1,200,000 2.40%
the financial
Internal failure costs:
Net cost of scrap 900,000 1.80% 750,000 1.50% consequences
Rework labor and overhead 1,430,000 2.86% 810,000 1.62%
Downtime due to defects in quality 170,000 0.34% 100,000 0.20% of the
Disposal of defective products
Total internal failure cost
500,000
3,000,000
1.00%
6.00%
340,000
2,000,000
0.68%
4.00% company’s
External failure costs:
current defect
Warranty repairs
Warranty replacements
400,000
870,000
0.80%
1.74%
900,000
2,300,000
1.80%
4.60%
rate.
Allowances 130,000 0.26% 630,000 1.26%
Cost of field servicing 600,000 1.20% 1,320,000 2.64%
Total external failure cost 2,000,000 4.00% 5,150,000 10.30%
Total quality cost $ 7,500,000 15.00% $ 9,000,000 18.00%

* As a percentage of total sales. In each year sales totaled $50,000,000.


McGraw-Hill Education (Asia) Slide 80
Quality Cost Reports in Graphic Form
$10 20

9
Quality 18

Quality Cost as a Percentage of Sales


8
reports 16
Quality Cost (in millions)

7
External External
can also 14
External External
6 Failure Failure be 12 Failure Failure

5 prepared 10

4 Internal
Failure
in 8 Internal
Failure
3 Internal
Failure
graphic 6 Internal
Failure
2
Appraisal form. 4
Appraisal
Appraisal Appraisal
1 2
Prevention Prevention Prevention Prevention
0 0
1 2 1 2
Year Year
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 81
Uses of Quality Cost Information

Help managers see the


financial significance of
defects.

Help managers identify


the relative importance
of the quality problems.
Help managers see
whether their quality
costs are poorly
distributed.
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 82
Limitations of Quality Cost Information
Simply measuring and
reporting quality cost
problems does not solve
quality problems.

Results usually lag


behind quality
improvement programs.

The most important


quality cost, lost sales, is
often omitted from
quality cost reports.
McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 83
ISO 9000 Standards
ISO 9000 standards have become
international measures of quality.
To become ISO 9000 certified, a
company must demonstrate:
1. A quality control system is in use, and the
system clearly defines an expected level of
quality.
2. The system is fully operational and is
backed up with detailed documentation of
quality control procedures.
3. The intended level of quality is being
achieved on a sustained basis.

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 84
End of Chapter 2

McGraw-Hill Education (Asia) Garrison, Noreen, Brewer, Cheng & Yuen Slide 85

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