CHAPTER 12

ACTIVITY-BASED MANAGEMENT
DISCUSSION QUESTIONS

1. The two dimensions are the cost dimension those costs caused by non-value-added
and the process dimension. The cost activities. An example is the cost of materials
dimension is concerned with accurate handling.
assignment of costs to cost objects, such as 6. (1) Activity elimination: the identification and
products and customers. Activity-based elimination of activities that fail to add
costing is the focus of this dimension. The value. (2) Activity selection: the process of
second dimensionthe process dimension choosing among different sets of activities
provides information about why work is done caused by competing strategies. (3) Activity
and how well it is done. It is concerned with reduction: the process of decreasing the
cost driver analysis, activity analysis, and time and resources required by an activity.
performance measurement. This dimension (4) Activity sharing: increasing the efficiency
offers the connection to the continuous of necessary activities using economies of
improvement world found in the advanced scale.
manufacturing environment.
7. A kaizen standard is the planned improvement
2. Driver analysis is concerned with identifying for the coming period. The kaizen subcycle
the root causes of activity costs. Knowing implements the improvement, checks it, locks
the root causes of activity costs is the key to it in, and then begins a search for additional
improvement and innovation. Once a improvements. The maintenance subcycle
manager understands why costs are being sets a standard based on prior improvements,
incurred, then efforts can be taken to executes, and checks the results to make sure
improve cost efficiency. Driver analysis is a that performance conforms to the new results.
part of process value analysis along with If not, then corrective action is taken.
activity analysis and performance
measurement. 8. Benchmarking identifies the best practices of
comparable internal and external units. For
3 Activity analysis is concerned with internal units, information can be gathered
identifying activities performed by an that reveals how the best unit achieves its
organization, assessing their value to the results; these procedures can then be
organization, and selecting and keeping adopted by other comparable units. For
only those that are value-added. Selecting external units, the performance standard
and keeping value-added activities bring provides an incentive to find ways to match
about cost reduction and greater operating the performance. (It may sometimes be
efficiency, thus providing support for the possible to determine the ways the
objective of continuous improvement. performance is achieved.)
4. Value-added activities are necessary 9. Activity flexible budgeting differs from unit-
activities. Activities are necessary if they are based flexible budgeting by using flexible
mandated or if they are not mandated and budget formulas based on both unit-level
satisfy three conditions: (1) they cause a and non-unit-level drivers. Unit-based
change of state, (2) the change of state is not flexible budgeting uses only unit-level
achievable by preceding activities, and drivers in its formulas.
(3) they enable other activities to be
performed. Value-added costs are costs 10. Planning should identify the purposes and
caused by activities that are necessary and objectives of an ABM system, its timeline for
efficiently executed. implementation, the assigned
responsibilities, the resources required, the
5. Non-value-added activities are unnecessary current and desired future competitive
activities or necessary activities that are position, the business processes and product
inefficient and improvable. An example is mix, and the ability of the organization to
moving goods. Non-value-added costs are

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 implement the new system and learn how to information with which they are already
use the new information produced. familiar.
11. ABM focuses on improving the efficiency of 14. A financial-based responsibility accounting
activities and thus needs detailed descriptions system is characterized by four elements:
of what makes up each activity. Knowing the (1) a responsibility center, where
tasks that define an activity makes it possible responsibility is assigned to an individual in
to change the way the activity is done so that charge (responsibility is usually defined in
overall activity performance improves. financial terms); (2) the setting of budgets
and standards to serve as benchmarks for
12. An ABM implementation may lose
performance measurement; (3)
managements support if it takes too long or
measurement of performance by comparing
if it fails to produce the expected results.
actual outcomes with budgeted outcomes;
Often, the expected results do not
and (4) individuals being rewarded or
materialize because managers do not know
penalized according to management
how to use the new information, suggesting
policies.
a lack of training and education in the new
systems capabilities. If the advantages of 15. In an activity-based responsibility accounting
the new ABM system are not detailed, then system, the focus of control shifts from
managers are likely to resist the new responsibility centers to processes and
system. teams. Management is concerned with how
work is done, not with where it is done.
13. A lack of integration often means that ABM
Process
is in direct competition or is perceived to be
improvement and process innovation are
in direct competition with other continuous
emphasized. Standards tend to be optimal,
improvement methods and the official
dynamic, and process oriented. Performance
accounting system. This state may cause
measurement focuses on processes and
managers to reject the new ABM
activities that define the processes. Finally,
approaches and rely on continuous
there tends to be more emphasis on group
improvement methods and accounting
rewards rather than on individual rewards.

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 CORNERSTONE EXERCISES

Cornerstone Exercise 12.1

1. Value and Non-Value-Added Cost Report
For the Year Ended 2015
Value-Added Non-Value-Added Total
Activity Costs Costs Costs
Receiving......................... $ 252,000 $126,000 $ 378,000
Assembly.......................... 1,125,000 225,000 1,350,000
Expediting........................ 0 300,000 300,000
Storing.............................. 0 84,000 84,000
Total............................. $1,377,000 $735,000 $2,112,000

2. Both expediting and storing are unnecessary activities. Both use resources
without bringing about any change of state.

3. For receiving, cost reduction occurs only when the actual demand for
receiving orders is reduced by each block of 1,500 orders. For assembly,
each hour saved produces a savings of $15. Accordingly, reduction in
spending will likely materialize more quickly for assembly than for receiving.

Cornerstone Exercise 12.2

1. Trend Report: Non-Value-Added Costs
Activity 2014 2015 Change
Receiving................................................... $126,000 $ 0 $126,000
Assembly.................................................... 225,000 45,000 180,000
Expediting.................................................. 300,000 150,000 150,000
Storing........................................................ 84,000 42,000 42,000
Total....................................................... $735,000 $237,000 $498,000
The trend report shows that the company significantly reduced non-value-
added costs, validating the improvement actions taken and enhancing its
competitive position.

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Cornerstone Exercise 12.2 (Concluded)
3. From Requirement 1, the savings per unit of product are $24.90
($498,000/20,000), indicating that the competitors price reduction cannot be
matched (or beat) without changing the unit profit margin that existed at the
beginning of the year. Another $2.10 per unit ($42,000/20,000) of non-value-
added cost must be reduced. I would recommend matching the price
reduction to ensure no loss of market share, with the expectation that the
next year improvement will produce at least another $42,000 of savings.

Cornerstone Exercise 12.3

1. Setup standard: 10 hours per batch; Expected cost per batch: $200 (10
$20); Kaizen standard: 6 hours per batch (0.60 10); Expected cost per batch:
$120 (6 $20).

2. Setup standard: 6 hours per batch; Expected cost per batch: $120
(6 $20). After determining that the suggested improvement
works and is sustainable, the new level of performance is locked
in by revising the maintenance standard from ten hours to six
hours. The next step is to search for another improvement
opportunity that will then produce a new kaizen standard and
expected batch cost. The ultimate objective is to eliminate all the
non-value-added cost through a series of kaizen improvements.

3. You lock in the level actually achieved by the suggested improvement

method. In this case, the maintenance standard would be 7 hours (0.70 10)
and the standard batch cost $140 (7 $20). Revisions should be based on
actual improvements achieved and the sustainability of these improvements.

Cornerstone Exercise 12.4

1. Acquired in advance of usage:
Welding equipment $ 48,000 (4 $12,000)
Welders 300,000 (6 $50,000)
Total fixed costs $348,000
Acquired as needed:
Welding supplies: $300/3 = $100 per welding hour (X)
Formula: Welding cost = $348,000 + $100X

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Cornerstone Exercise 12.4 (Concluded)
2. Activity-Based Performance Report
Budgeted Cost Budget
Activity Actual Cost (90% level)* Variance**
Welding:
Fixed cost........................ $363,000 $348,000 $15,000 U
Variable cost................... 805,000 810,000 5,000 F
*$348,000 (fixed); $100 0.90 9,000 (variable)
**Actual cost less budgeted cost
3. Welding cost = $48,000 + $130X (The cost of welding equipment is fixed; the
variable cost is the $30 per hour of contract welding labor plus the $100
per hour for parts and supplies.)

Cornerstone Exercise 12.5

1. Purchasing is a value-added activity with SQ = 7,000. Thus,
Volume variance = (AQ SQ)SP
= (12,000 7,000)$19*
= $95,000 U
*Activity rate = ($45,600 5)/12,000
The volume variance is a measure of the non-value-added cost. In this case,
only about 42 percent of the total activity cost is non-value-added.
Management should strive to find ways to reduce and eventually eliminate
the non-value-added component of the purchasing activity.
2. Unused capacity variance = (AU AQ)SP
= (10,600 12,000)$19
= $26,600 F
The demand for the activity has been reduced; however, because of the step-
fixed cost nature of purchasing labor, the reduction is not sufficient to
produce a reduction in activity spending.
3. Recalculating the unused capacity variance:
Unused capacity variance = (AU AQ)SP
= (9,000 12,000)$19
= $57,000 F
At this level of demand, only four inspectors are needed to meet the demand;
thus, resource spending can be reduced by $45,600. If only 7,000 orders are
needed, then 7,000/2,400 = 2.92, which implies that three purchasing agents
will be required. Thus, resource spending can be reduced by the cost of two
agents: 2 $45,600 = $91,200. This is the maximum reduction if SQ is
reached.

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 EXERCISES

Exercise 12.6
1. Plantwide rate = ($5,400,000 + $3,600,000 + $1,800,000)/90,000
= $120 per machine hour
Unit overhead cost = ($120 50,000)/100,000 = $60
Activity rates:
Machining rate = $5,400,000/90,000 = $60 per assembly hour
Inspection rate = $3,600,000/45,000 = $80 per inspection hour
Rework rate = $1,800,000/45,000 = $40 per rework hour
Total overhead cost = ($60 50,000) + ($80 10,000) + ($40 7,500)
= $4,100,000
Unit overhead cost = $4,100,000/100,000 = $41
Improving the accuracy reduced the cost by $19, which is still less than the
$20 reduction needed. What this means is that although accuracy has a
positive effect on the price, it is not the only problem. It appears that
competitors may be more efficient than Harvey. This outcome then signals
the need to
reduce costs.

2. Since inspection and rework costs and their associated time are both
reduced by 50 percent, the activity rates remain the same, although the
amount of cost assigned to the Special model will change:
Total overhead cost = ($60 50,000) + ($80 5,000) + ($40 3,750)
= $3,550,000
Unit overhead cost = $3,550,000/100,000 = $35.50
The cost now is $24.50 less than the original, which allows management to
reduce the price by $20, increasing the competitive position of the Special
model. ABC is concerned with how costs are assigned, whereas ABM is not
only concerned with how they are assigned but also with how costs can be
reduced. Cost accuracy and cost reduction are the dual themes of ABM.

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Exercise 12.7

The following are possible sets of questions and answers (provided as examples
of what students may suggest):

Cleaning oil:

Question: Why is the oil puddle cleaned daily?

Answer: Because the production equipment leaks oil every day.

Question: Why does the production equipment leak oil?

Answer: Because a seal is damaged (root cause).

Question: How do we repair the damaged seal?

Answer: By replacing it.

Providing sales allowances:

Question: Why are we giving sales allowances?

Answer: Because the product is not working as it should.

Question: Why is the product not working as it should?

Answer: Usually because it has a defective component.

Question: Why does it have a defective component?

Answer: Because our subassembly processes occasionally produce bad
components.

Question: Why do our subassembly processes produce bad components?

Answer: Because our workers are not as well trained as they should be (root
cause).

Question: How do we improve the skills of our workers?

Answer: By ensuring that they all pass a rigorous training course.

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Exercise 12.8

Non-value-added:
Comparing documents (state detection)$144,000 (0.12 $1,200,000)
Resolving discrepancies (rework) $876,000 (0.73 $1,200,000)

Value-added:
Preparing checks$120,000 (0.10 $1,200,000)
Mailing checks $60,000 (0.05 $1,200,000)

Exercise 12.9

Questions 26 represent a possible sequence for the activity of comparing

documents, and Questions 1 and 36 represent a possible sequence for
resolving
discrepancies. The two activities have a common root cause.

Question 1: Why are we resolving discrepancies?

Answer: Because the purchase order, receiving order, and invoice have been
compared and found to be in disagreement.

Question 2: Why are documents being compared?

Answer: Because they may not agree.

Question 3: Why would the documents not agree?

Answer: Because one or more may be wrong.

Question 4: Why would a document be wrong?

Answer: Because the amount received from the supplier may not correspond
to the amount ordered or because the amount billed may not
correspond to the amount received or both.

Question 5: Why are the amounts different?

Answer: Because of clerical erroreither by us or by the supplier.

Question 6: How can we avoid clerical error?

Answer: Training for our clerks will reduce the number of discrepancies; for
suppliers, extra training and care can be suggested where there is
evidence of a problem.

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Exercise 12.10
1. A process is a collection of activities with a common objective. The common
objective of procurement is to supply bought and paid-for materials to
operations (e.g., the manufacturing process). The common objective of
purchasing is to produce a request for materials from suppliers; the common
objective of receiving is to process materials from suppliers and move them
to the operations area (e.g., stores or manufacturing); the common objective
of paying bills is to pay for the materials received from suppliers.

2. The effect is to reduce the demand for the activity of resolving discrepancies
by 30 percent. By so doing, Thayne will save 21.9 percent (0.30 0.73) of its
clerical time. Thus, about six clerks can be eliminated by reassigning them
to other areas or simply laying them off. (30 .219 = 6.57 clerks but only 6
can be eliminated or reassigned because they are lumpy resources). This
will produce savings of about $$240,000 (6 $40,000) per year. This is an
example of process improvementan incremental increase in process
efficiency resulting in a cost reduction.

Exercise 12.11

EDI eliminates the demand for virtually all the activities within the bill-paying
process. Some demand may be left for payment activities relative to the
acquisition of nonproductive supplies. Assuming conservatively that 90 percent
of the demand is gone, there would be a need for three clerks (30 (0.90 30)).
This would save the company $1,080,000 ((30 3) $40,000) per year for this
subprocess alone. Additional savings would be realized from reduction of
demands for purchasing and receiving activities. Switching to an EDI
procurement structure is an example of process innovation.

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Exercise 12.12

Case Non-Value-Added Cost Root Cause Cost Reduction

1 $22 per unita Process design Activity selection
2 $2,900 per setupb Product design Activity reduction
3 $80 per unitc Plant layout Activity elimination
4 $136,000 per yeard Multiple* Activity elimination
5 $180 per unite Suppliers Activity selection
6 $900,000 per yearf Product design Activity sharing
a
(0.75 0.25)$12 + (6 4)$8
b
(15 0.5)$200
c
(8 0)$10
d
$120,000 + (8,000)$2
e
(5.3 5)$600
f
As given.
*For example, process design, product design, and quality approach or
philosophy.

Exercise 12.13
1. Fixed activity rate = SP = $504,000/28,000 = $18 per setup hour
Cost of unused capacity:
SP SQ SP AQ SP AU
$18 2,000 $18 28,000 $18 26,200
$36,000 $504,000 $471,600
$468,000 U $32,400 F
Volume Variance Unused Capacity Variance
The activity volume variance measures the non-value-added cost.
The unused capacity variance is a measure of the potential to reduce the
spending on an activity and, thus, reduce the non-value-added costs. In this
case, since the resource is acquired one person at a time, there is not
sufficient unused capacity to reduce the number of employees by one. The
favorable unused capacity variance does signal that the activity demand is
being reduced. Whenever the unused activity reaches 2,000 hours, then
resource spending can be reduced. (The objective is to reduce the number of
hours used to 2,000, eliminating all of the non-value-added cost.)

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Exercise 12.13 (Concluded)
2. Value-added costs = $18 2,000 = $36,000
Non-value-added costs = $18 26,000 = $468,000
A value-added cost report would be as follows:
Value-Added Non-Value-Added Actual
Setting up.................................. $36,000 $468,000 $504,000
Highlighting non-value-added costs shows managers where savings are
possible and emphasizes the need for improvement. In this case, reducing
setup hours to 2,000 will create unused capacity of 26,000 hours, allowing
the company to save $468,000 in salaries.

3. By reducing the demand to 4,000 hours, the unused capacity now equals
24,000 hours (28,000 4,000). Thus, the company has 12 more employees
than needed (24,000/2,000 = 12). Accordingly, the number of employees can
be reduced from 14 to two, saving $432,000.

4. Inspection is a state-detection activity and not state changing and is,

therefore, non-value-added. It exists because suppliers must be producing a
significant number of defective materials (components). It does produce
benefits in the sense that culling out defective units or rejecting especially
bad shipments will reduce costs downstream (e.g., rework and warranty
costs). This reveals the possibility that non-value-added activities may
produce benefitsat least in the short run. However, while the cost of the
inspecting activity may be justified as a temporary measure by virtue of its
downstream savings, these same savings can be realized plus additional
savings if the root causes of the inspecting activity are identified and
corrected so that the need for inspecting vanishes. Since the root cause is
bad supplier components, the correct solution is finding/developing
suppliers that provide components with a very low defect rate, thus
eliminating the need to inspect.

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Exercise 12.14
1. Sanford, Inc.
Value- and Non-Value-Added Cost Report
For the Year Ended December 31, 2015
Value-Added* Non-Value-Added** Actual
Purchasing parts................. $ 780,000 $ 312,000 $ 1,092,000
Receiving parts.................... 1,014,000 507,000 1,521,000
Moving parts........................ 0 1,014,000 1,014,000
Setting up equipment.......... 0 1,216,800 1,216,800
Total................................. $1,794,000 $3,049,800 $4,843,800

*SP*SQ; **(AQ SQ)SP

2. Moving parts is non-value-added (SQ = 0 is a necessary condition for a non-

value-added activity). Moving parts does produce a change in state
(changing location is a state change as parts must be located where they are
needed). Yet, by proper design of the plant layout and by installing the right
inventory management procedures, it is possible to make material movement
virtually insignificant. In other words, a change in state is made unnecessary.
Setting up equipment seems necessary and therefore value-added. Yet, if the
time is reduced to zero, setup costs are reduced to zero; thus, in this case,
the activity behaves as if it were non-value-added. It seems logical that if the
non-value-added cost component is 100 percent of the activity cost, then it
should be a non-value-added activity. Value-added activities can engender
non-value-added costs if they are not performed efficiently (but there should
be a value-added cost component in the efficient state).

Exercise 12.15
1. Sanford, Inc.
Non-Value-Added Cost Trend Report
For the Year Ended December 31, 2016
2015 2016 Change
Purchasing parts................................. $ 312,000 $ 156,000 $ 156,000
Receiving parts.................................... 507,000 253,500 253,500
Moving parts......................................... 1,014,000 331,800 682,200
Setting up equipment.......................... 1,216,800 304,200 912,600
Total.................................................. $3,049,800 $1,045,500 2,004,300
Note: The above amounts were computed for each year, using the following
formula: (AQ SQ)SP.

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Exercise 12.15 (Concluded)
2. For non-value-added activities, activity reduction can serve to reduce the
demand for these activities with the ultimate objective of reducing the
demand to zero. For value-added activities, activity reduction is used to
eliminate the non-value-added component.

3. A trend report allows managers to assess the effectiveness of activity

management. It is a critical document that reveals the success of continuous
improvement efforts. It also provides some information about additional
opportunity for improvement. In 2016, activity management reduced the non-
value-added costs by $2,004,300, signaling that the actions taken were good.
It also shows that additional opportunity for reduction existsmore effort is
needed to reduce the $1,045,500 of remaining non-value-added costs.

Exercise 12.16
The ABM implementation is taking too long and is not producing the
expected
results. It also appears to not be integrated with the divisions
official accounting system, encouraging managers to continue
relying on the old system (as evidenced by the continued reliance on
traditional materials and labor efficiency
variances). The fact that the ABC product costs are not significantly
different in many cases could be due to a lack of product diversity or
perhaps due to poor choice of pools and drivers. The lack of a
competitive cost state suggests the presence of significant non-
value-added costs. The emphasis on the absence of product cost
differences, lack of cost reductions, and the attitude about activity
detail and the value content of inspection all reveal that plant
managers have very limited understanding about ABM and what it
can do. There clearly needs to be a major effort to train managers to
understand and use activity data. At this point, no organizational
culture emphasizes the need for continuous improvement. This need
and the role ABM plays in continuous improvement needs to be
taught. The new ABM system also needs to be integrated to
maximize its chances for success.

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Exercise 12.17

Classification:

Situation Activity-Based Financial-Based

1 A B
2 A B
3 A B
4 B A
5 B A
6 B A
7 A B

Comments:

Situation 1: In a financial-based system, individuals are held responsible for the

efficiency of organizational units, such as the Grinding Department. In an activity-
based system, processes are the control points because they are the units of
change; they represent the way things are done in an organization. Improvement
and innovation mean changing the way things are done, or in other words,
changing processes. Since processes, such as procurement, cut across
functional boundaries, teams are the natural outcome of process management. It
is only natural that the managers of Purchasing, Receiving, and Accounts
Payable be part of a team looking for ways to improve procurement.

Situation 2: In a financial-based responsibility system, individuals in charge of

responsibility centers are rewarded based on their ability to achieve the financial
goals of the responsibility center. Thus, meeting budget promises the fat bonus.
In a continuous improvement environment, process improvement is dependent on
team performance, so rewards tend to be group based, and gainsharing is often
used. Furthermore, there are many facets to process performance other than cost,
so the performance measures tend to be multidimensional (e.g., quality and
delivery time).

Situation 3: In a financial-based system, efforts are made to encourage individuals

to maximize the performance of the subunit over which they have responsibility.
The concern of activity-based responsibility accounting is overall organizational
performance. The focus is systemwide. It recognizes that maximizing individual
performance may not produce firmwide efficiency.

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Exercise 12.17 (Concluded)

Situation 4: In a financial-based system, performance of subunits is usually

financial-based and is measured by comparing actual with budgeted outcomes.
In an activity-based system, process performance is emphasized. The objective
is to provide low-cost, high-quality products, delivered on a timely basis. Thus,
both financial and nonfinancial measures are needed.

Situation 5: In a financial-based system, budgets and standards are used to

control costs. In an activity-based responsibility system, the focus is on activities
because activities are the cause of costs. Driver analysis and activity analysis are
fundamental to the control process. Driver analysis recognizes that controlling
costs requires managers to understand the root causes. Activity analysis is the
effort expended to identify, classify, and assess the value content of all activities.
Once the value content is known, then costs can be controlled through such
means as activity reduction, activity elimination, activity sharing, and activity
selection.

Situation 6: A financial-based system uses currently attainable standards that

allow for a certain amount of inefficiency. Achieving standards is the emphasis,
and there is no effort to improve on the standards themselves. An activity-based
approach strives for the ideal and so the standard is the ideal. Progress is
measured over time with the expectation that performance should be continually
improving. Efforts are made to find new ways of doing things and thus to find
new optimal standards. The objective is to always provide incentives for positive
changes.

Situation 7: The financial-based system tends to ignore a firms activities and the
linkages of those activities with suppliers and customers. It is internally focused.
An activity-based system builds in explicit recognition of those linkages and
emphasizes the importance of the value chain. Furthermore, the assessment of
the value content of activities is explicitly related to customers. What goes on
outside the firm cannot be ignored.

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 CPA-TYPE EXERCISES

Exercise 12.18

d. Assembling, purchasing, and designing new produces are all necessary

activities and thus value added. Rework is redoing work that should have
been done correctly the first time and is therefore nonvalue-added.

Exercise 12.19

a. Inspecting and rework are both nonvalue-added activities and the total cost of
the two activities is $126,000.

Exercise12.20

b. Activity elimination is the correct answer as rework is a nonvalue-added

activity and should be eliminated.

Exercise 12.21

a. The other answers are features of activity-based costing.

Exercise 12.22

c. The total activity capacity is 20,000 moves (4 5,000). Thus, the

unused capacity is 2,000 moves. Each move has a price of $3.60
($18,000/5,000 or $72,000/20,000). Thus, the cost of the unused
capacity is $3.60 2,000 = $7,200.

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 PROBLEMS

Problem 12.23
1. An activity driver measures the amount of an activity consumed by a cost
object. It is a measure of activity output. Activity drivers are used to assign
activity costs to cost objects. On the other hand, a cost driver is the root
cause of the activity and explains why the activity is performed. Cost drivers
are useful for identifying how costs can be reduced (rather than assigned).

2. Value content and driver analysis:

Setting up equipment: At first glance, this appears to be a value-added
activity because (1) it causes a change in the state of nature: improperly
configured equipment to properly configured equipment, (2) there is no prior
activity that should have caused the state change, and (3) it is necessary to
enable other activities to be performed. However, setting up equipment often
takes more time than needed and so has a non-value-added component.
Most companies strive for zero setup time, suggesting that the time and
associated cost are non-value-added because the activity is performed
inefficiently. (A zero setup time suggests a non-value-added activity.) Means
should be explored to reduce the time of this activity so that it consumes
less resources. Possible root causes include such factors as product design,
process design, and equipment design. Knowing the root causes can lead to
an improvement in activity efficiency. Moving from a departmental
manufacturing structure to a cellular manufacturing structure in some cases
may eliminate the need for setups, thus eliminating the activity. Or flexible
manufacturing equipment might be purchased that provides an almost
instantaneous setup capability (a change in process technologyand
certainly a change in equipment design). In other cases, the activity may be
improved by redesigning the product so that a less complicated setup is
required.
Performing warranty work: This is generally viewed as a non-value-added
activity and should be eliminated. It is non-value-added because it represents
a type of reworkrepairs on products that are caused by faulty production.
Possible root causes include poor vendor quality, poor product design,
quality management approach, and manufacturing process used. Knowing
the root causes may lead to a supplier valuation program that improves the
quality of the parts and materials purchased externally, adoption of a total
quality management program, product redesign, process redesign, and
perhaps the use of automated equipment to cut down on faulty products.

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Problem 12.23 (Continued)
Welding subassemblies: This is a value-added activity. It causes a desired
state change that could not have been done by preceding activities and
enables other activities to be performed. If inefficient, then means should be
sought to improve efficiency. The goal is to optimize value-added activity
performance. Possible root causes of inefficiency include product design,
process design, and production technology. Changing either product or
process design could decrease the demand for the welding activity while
producing the same or more output. A change in technologybuying more
advanced technology, for examplemay also increase the efficiency of the
activity.
Moving materials: This is usually viewed as a non-value-added activity.
Moving materials and subassemblies from one point in the plant changes
location but not the state. But it does enable other activities to be performed,
and it is not a repeated action. If it is argued that changing location is a
change in state, then you could respond by noting that it is an unnecessary
change of state. Possible root causes include plant layout, manufacturing
processes, and vendor arrangements. Moving from a departmental to a
cellular structure, adopting computer-aided manufacturing, and entering into
contracts with suppliers that require just-in-time delivery to the point of
production are examples of how knowledge of root causes can be exploited
to reduce and eliminate materials handling cost.
Inspecting components: Inspection is a non-value-added activity. It is a state-
detection activity and is not necessary to enable other activities to be
performed. This activity should be reduced and eventually eliminated. A
possible root cause of inspection is the possibility of poor quality of parts
and materials. The company should work with suppliers to ensure high
quality (zero-defect parts).

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Problem 12.23 (Concluded)
3. Behavioral analysis:
Setting up equipment: Using the number of setups as a driver may cause a
buildup of inventories. Since reducing the number of setups will reduce
setup costs, there will be an incentive to have fewer setups. Reducing the
number of setups will result in larger lots and could create finished goods
inventory. This is in opposition to the goal of zero inventories. On the other
hand, if setup time is used as the driver, managers will have an incentive to
reduce setup time. Reducing setup time allows managers to produce on
demand rather than for inventory.
Performing warranty work: Using the number of defective units as a driver
should encourage managers to reduce defective units. Assuming that
defective units are the source of warranty work, this should reduce warranty
costs. Similarly, using warranty hours could encourage managers to find
ways to reduce warranty work by decreasing its causes. Alternatively, it may
cause them to look for more efficient means of performing warranty work.
Increasing the efficiency of a non-value-added activity has some short-run
merit, but it should not be the focus. Of the two drivers, defective units is the
most compatible with eventual elimination of the non-value-added activity.
Welding subassemblies: Using welding hours should encourage management
to find ways of reducing the welding hours required per product. This would
more likely induce managers to look at possible root causes such as product
design and process design than would number of welded subassemblies.
There is some value in looking for ways to reduce the number of welded
subassemblies, perhaps redesigning the product to eliminate welding.
Moving materials: Both drivers seem to have positive incentives. Seeking
ways to reduce the number of moves or distance moved should lead
managers to look at root causes. Reorganizing the plant layout, for example,
should reduce either the number of moves or the distance moved. Hopefully,
the activity drivers will lead to the identification of executional drivers that
can be managed so that the activity can be reduced and eventually
eliminated.
Inspecting components: Hours of inspection can be reduced by working with
suppliers so that greater incoming quality is ensured. Similarly, the number
of defective parts can be reduced by working with suppliers so that incoming
quality is increased. Hours of inspection, however, can be reduced without
increasing quality. This is not true for the number of defective parts. Using
the number of defective parts appears to be a better choice.

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Problem 12.24
1. First quarter: Setup time standard = 9 hours (based on the planned
improvement: 12 hours 3 hours of reduced time)
Second quarter: Setup time standard = 1 hour (based on the planned
improvement: 7 hours 6 hours)

2. Kaizen subcycle:
Plan (3-hour reduction from process redesign.)
Do (Try out setup with new design.)
Check (Time required was seven hours, a 5-hour reduction.)
Act (Lock in 5-hour improvement by setting new standard of seven hours
and using same procedures as used to give the 7-hour outcome;
simultaneously, search for new improvement opportunityin this case,
the suggested changes of the production workers.)
Repeat kaizen subcycle:
Plan (6-hour reduction from setup procedure changes.)
Do (Train and then implement procedures.)
Check (Actual time required was three hours, a 4-hour reduction.)
Act (Lock in improvement by setting standard of three hours and begin
search for new improvement.)

3. Maintenance subcycle for setups:

First quarter (12-hour standard at the beginning of the quarter):
Establish standard (Seven hours based on actual improved process
design.)
Do (Implement repetitively the improved standard.)
Check (See if the 7-hour time is maintained.)
Act (If the 7-hour time deteriorates, find out why and take corrective action
to restore to seven hours.)
Second quarter (7-hour standard at the beginning):
Same cycle using three hours as the new standard to maintain.
Note: The new maintenance cycle begins after observing the actual
improvement. The actual improvement is locked in.

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Problem 12.24 (Concluded)
4. Non-value-added cost saved (eliminated) with 9 hours of reduced setup-time:
$600 9 = $5,400 per setup. Kaizen costing is concerned with improving
activity performance and uses root causes to help identify initiatives for
improvement. Thus, kaizen is a tool or means for implementing ABM
concepts.

5. Kaizen costing emphasizes constantly searching for process improvements

with the standard changing with each improvement. This search involves all
employees (e.g., engineers and production workers). Thus, kaizen costing
focuses on processes and uses dynamic standards, which are
characteristics of activity-based responsibility accounting. Standard costing
uses only the maintenance subcycle. Standards are set and maintainedthey
are static in nature and thus consistent with the financial-based
responsibility accounting model.

Problem 12.25
1. Formula
Resource Fixed Variable
Salaries........... $1,250,000
Lease............... 144,000
Crates.............. $1.80
Fuel................. 0.36*
Total........... $1,394,000 $2.16
*$3.60/10 cycles

2. Capacity is determined by the minimum of forklift capacity and operator

capacity. Forklift capacity is 3 24 280 8 = 161,280 moves, or 80,640
cycles. Operator capacity is 3 25 2,000 = 150,000 moves, or 75,000 cycles.
Thus, 75,000 cycles is the activity capacity and 80 percent of that capacity is
60,000 cycles.
Budget:
Formula 60,000 Cycles
Resource Fixed Variable (Activity Output)
Salaries............. $1,250,000 $ 1,250,000
Lease................ 144,000 144,000
Crates............... $1.80 108,000
Fuel................... 0.36 21,600
Total............... $1,394,000 $2.16 $1,718,6000

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Problem 12.25 (Concluded)
Novo, Inc.
Performance Report
For the Year 20XX
Resource Actual Costs Budgeted Costs Budget Variance
Salaries...................... $1,290,000 $1,250,000 $40,000 U
Leases....................... 144,000 144,000 0
Crates......................... 118,200 108,000 10,200 U
Fuel............................ 24,000 21,600 2,400 U
Total...................... $1,576,200 $1,523,600 $52,600 U

3. SQ = 0 and so the volume variance is the capacity acquisition cost:

$1,394,000.

4. Formula 25,000 Cycles

Resource Fixed Variable (Activity Output)
Salaries...................... $450,000 $450,000
Leases....................... 54,000 54,000
Crates......................... $1.80 45,000
Fuel............................ 0.36 9,000
Total...................... $494,000 $2.16 $558,000
Note: Reducing demand permanently to 25,000 cycles requires nine
operators. Each operator provides a capacity of 3,000 cycles [(2,000 hours
3)/2]; thus, for a 25,000-cycle demand, we need 25,000/3,000 = 8.33 = 9
operators and three forklifts. Each forklift provides a capacity of 10,080
cycles [(3 24 280)/2]; thus, 25,000/10,080 = 2.48 = 3 forklifts. This
illustrates the lumpy nature of resources and their role in budgeting.
Clearly, the cost of performing this activity has been dramatically reduced.
(Compare the budgeted cost of the 80 percent capacity, $1,718,600, with the
$558,000.) This is the critical performance measure. The activity performance
report in Requirement 2 simply compares the budgeted costs for 80 percent
capacity for the various activity inputs with the actual input costs. It makes
no statement about the waste in the activity itself (which is all waste because
it is a non-value-added activity).

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Problem 12.26
1. Activity-based management is a systemwide, integrated approach that
focuses managements attention on activities. It involves two dimensions: a
cost dimension and a process dimension. Key elements in activity
management include identifying activities, assessing their value, and
retaining only value-added activities. ABM connects with continuous
improvement by identifying root causes of non-value-added activities and
using these root causes to eventually eliminate non-value-added activities
and thus reduce costs. ABM also focuses on increasing the efficiency of
value-added activities.

2. Setting up equipment................................................ $ 187,500

Materials handling..................................................... 270,000
Inspecting products.................................................. 183,000
Handling customer complaints................................ 150,000
Filling warranties....................................................... 255,000
Storing goods............................................................ 120,000
Expediting goods...................................................... 112,500
Total....................................................................... $1,278,000
Units produced and sold.......................................... 120,000*
Potential unit cost reduction.................................... $ 10.65
*$2,880,000/$24 (Total cost divided by unit cost)
The consultants estimate of cost reduction was on target. Per-unit costs can
be reduced by at least $10.50, and further reductions may be possible if
improvements in value-added activities are possible. Actions to reduce or
eliminate non-value-added activities include improving quality, redesigning of
products, reengineering processes, and adopting a JIT purchasing and
manufacturing approach.

3. Target cost to maintain sales = $21 $6 = $15

Target cost to expand sales = $18 $6 = $12
Current cost = $24
Cost reduction to maintain = $24 $15 = $9
Cost reduction to expand = $24 $12= $12

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Problem 12.26 (Concluded)
4. Total potential reduction:
$1,278,000 (from Requirement 2)
225,000 (by automating)
$1,503,000
Units........................ 120,000
Unit savings........ $ 12.53 (rounded to nearest cent)
Costs can be reduced by at least $10.50, enabling the company to maintain
current market share. Further, with the additional reductions, if all the non-
value-added costs are eliminated, then the cost reduction needed to increase
market share is also possible. Activity selection is the form of activity
management used here.

5. Current:
Sales.................................. $3,240,000 ($27 120,000 units)
Costs................................. 2,880,000
Income.......................... $ 360,000
$21 price (assumes that current market share is maintained):
Sales.................................. $1,680,000 ($21 120,000)
Costs................................. 1,376,400 ($11.47* 120,000)
Income.......................... $ 1,143,600
$18 price:
Sales.................................. $3,240,000 ($18 180,000)
Costs................................. 2,064,600 ($11.47* 180,000)
Income.......................... $1, 175,400
*$24.00 $12.53 = $11.47
The $18 price produces the greatest benefit.

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Problem 12.27
1. Non-value-added usage and costs (first year):
Non-Value-Added Non-Value-Added
Usage Cost
AQ* SQ** AQ SQ (AQ SQ)SP
Molding.............. 2,700,000 2,160,000 540,000 $ 8,100,000
Engineering....... 144,000 86,400 57,600 2,016,000
$10,116,000
*1.25 9 240,000; (4 18,000) + (10 7,200) (AQ for engineering represents
the actual practical capacity acquired.)
**9 240,000; (0.60 72,000) + (0.60 72,000)
Note: SP for materials is $15; SP for engineering is $35 ($70,000/2,000). There
are no price variances because SP = AP.
Unused capacity for engineering:
SP AQ SP AU
$35 144,000 $35 138,000
$5,040,000 $4,830,000
$210,000 F
Unused Capacity Variance

2. Kaizen standards for the coming year (second year):

Molding: SQ = 2,160,000 + 0.7(540,000) = 2,538,000 pounds
Engineering: SQ = 86,400 + 0.7(57,600) = 126,720 engineering hours

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Problem 12.27 (Concluded)
3. AU* SQ AU SQ SP(AU SQ)
Materials.................... 2,600,000 2,538,000 62,000 $930,000 U
Engineering............... 120,000 126,720 (6,720) 235,200 F
*For engineering, the kaizen standard is a measure of how much resource
usage is needed (this year), and so progress is measured by comparing with
actual usage, AU, not AQ, activity availability. AQ AU, on the other hand,
will measure the unused capacity, a useful number, as is discussed below.
The company failed to meet the molding kaizen standard but beat the
engineering standard. The engineering outcome is of particular interest. The
actual usage of the engineering resource is 120,000 hours, and activity
availability is 144,000 hours. Thus, the company has created 24,000 hours of
unused engineering capacity. Each engineer brings a capacity of 2,000 hours.
Since engineers come in whole units, the company now has 12 too many!
Thus, to realize the savings for the engineering activity, the company must
decide how to best use these available resources. One possibility is to
simply lay off 12 engineers, thereby increasing total profits by the salaries
saved ($840,000). Other possibilities include reassignment to activities that
have insufficient resources. (For example, perhaps new product development
could use 12 engineers.) The critical point is that resource usage reductions
must be converted into reductions in resource spending, or the efforts have
been in vain.

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Problem 12.28
1. Current cost per unit = $28,800,000/20,000 = $1,440
Current profit per unit = $1,620 $1,440
= $180
Target cost (C) to maintain current profit and expand market share:
$1,404 C = $180
C = $1,224

2. Non-value-added costs:
Materials (900,000 855,000)$21............................. $ 945,000
Labor (216,000 205,200)$12.50.............................. 135,000
Setups (14,400 0)$75.............................................. 1,080,000
Materials handling (36,000 0)$70.......................... 2,520,000
Warranties (36,000 0)$100..................................... 3,600,000
Total....................................................................... $8,280,000
Units produced and sold.......................................... 20,000
Unit non-value-added cost.................................. $ 414
Current cost less non-value-added cost:
$1,440 $414 = $1,026
This is much less than the target cost of $1,224 or the Kansas City plants
cost of $1,260. Thus, matching the cost is possible and so is the target cost
for expanding market share. How quickly the cost reductions can be
achieved is another matter. Since the Kansas City plant has experience in
achieving reductions, it may be possible to achieve at least a cost of $1,260
within a reasonably short time. As plant manager, I would borrow heavily
from the Kansas City plant experience and attempt to reduce the non-value-
added costs quickly. I would also lower the price to $1,404 and seek to take
advantage of the increased market shareeven if it meant a short-term
reduction in profits.

3. Benchmarking played a major role. The Kansas City plant set the
standard and offered to share information on how it achieved the
cost reductions that enabled it to lower its selling price. The Tulsa
plant responded by accepting the offer of help and taking actions
to achieve the same or greater cost reductions.

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Problem 12.29
1. Actual Costs Budgeted Costs Budget Variance
Direct labor..................... $210,000 $200,000 $ 10,000 U
Power.............................. 135,000 85,000 50,000 U
Setups............................. 140,000 100,000 40,000 U
Total............................ $485,000 $385,000 $100,000 U
Note: Budgeted costs use the actual direct labor hours and the labor-based
cost formulas. Example: Direct labor cost = $10 20,000 = $200,000; Power
cost = $5,000 + ($4 20,000) = $85,000; Setup cost = $100,000 (fixed).

2. Actual Costs Budgeted Costs Budget Variance

Direct labor..................... $210,000 $200,000 $10,000 U
Power.............................. 135,000 149,000 14,000 F
Setups............................. 140,000 142,000 2,000 F
Total............................ $485,000 $491,000 $ 6,000 F
Note: Budgeted costs use the individual driver formulas: Direct labor = $10
20,000; Power = $68,000 + ($0.90 90,000); Setups = $98,000 + ($400 110)

3. The multiple cost driver approach captures the cause-and-effect cost

relationships and, consequently, is more accurate than the direct-labor-based
approach.

4. Agree. Non-value-added cost trend reports emphasize cost reduction and

thus are consistent with continuous improvement. Flexible budget perfor-
mance reportseven those using activity-based flexible budgets
emphasize static budgetary performance and ignore cost reduction.

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Problem 12.30
1. Marston, Inc.
Performance Report
For the Year 2015
Actual Costs Budgeted Costs* Budget Variance
Direct materials.............. $ 440,000 $ 480,000 $40,000 F
Direct labor..................... 355,000 320,000 35,000 U
Depreciation................... 100,000 100,000 0
Maintaining equipment.. 425,000 435,000 10,000 F
Machining....................... 142,000 137,000 5,000 U
Moving materials ........... 232,500 240,000 7,500 F
Inspecting products...... 160,000 145,000 15,000 U
Total............................ $1,854,500 $1,857,000 $ 2,500 F
*Budget formulas for each item can be computed by using the high-low
method (using the appropriate cost driver for each method). Using this
approach, the budgeted costs for the actual activity levels are computed as
follows:
Direct materials: $6.00 80,000
Direct labor: $4 80,000
Depreciation: $100,000
Maintaining equipment: $60,000 + ($1.50 250,000)
Machining: $12,000 + ($0.50 250,000)
Moving materials: $40,000 + ($6.25 32,000)
Inspecting products: $25,000 + ($1,000 120)

2. Pool rates: $1,100,000/100,000 = $11 per direct labor hour

$672,000/300,000 = $2.24 per machine hour
$290,000/40,000 = $7.25 per move
$225,000/200 = $1,125 per batch
Note: The first pool has material and labor cost included. The total for each
pool corresponds to the costs associated with a given driver in the flexible
budget. The totals correspond to the second activity level of the budget.
Unit cost:
Pool 1: $11 10,000.................... $110,000
Pool 2: $2.24 15,000................ 33,600
Pool 3: $7.25 500..................... 3,625
Pool 4: $1,125 5....................... 5,625
Total........................................ $152,850
Units............................................. 10,000
Total/Units.............................. $ 15.29

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Problem 12.30 (Concluded)
3. Knowing the resources consumed by activities and how the resource costs
change with the activity driver should provide more insight into managing the
activity and its associated costs. For example, moving materials is a non-
value-added activity, and efforts should be made to reduce the demands for
this activity. If moves could be reduced to 20,000 from the expected 40,000,
then costs can be reduced by not only eliminating the need for four
operators, but also by reducing the need to lease from four to two forklifts.
However, in the short run, the cost of leasing forklifts may persist even
though demand for their service is reduced.
20,000 Moves 40,000 Moves
Materials handling:
Forklifts......................................................... $ 40,000 $ 40,000
Operators...................................................... 120,000 240,000
Fuel................................................................ 5,000 10,000
Total........................................................... $165,000 $290,000
The detail assumes that forklift leases must continue in the short run but that
the number of operators may be reduced (assumes each operator can do
5,000 moves per year). If the two forklifts could be subleased, then an
additional savings of $20,000 would be realized. Thus, the budget reveals
that
reducing the demands for materials handling to 20,000 moves can save
between $125,000 and $145,000 (relative to the 40,000-move level). It also
provides the additional amount that could be saved if the activity demand is
reduced to zero (up to $165,000).

CYBER RESEARCH CASE

12.31

Answers will vary.

The Collaborative Learning Exercise Solutions can be found on the

instructor website at http://login.cengage.com.

The following problems can be assigned within CengageNOW and are auto-
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graded. See the last page of each chapter for descriptions of these new
assignments.

Integrative ProblemActivity Based Costing, Strategic Cost Management,

Activity Based Management (Covers chapters 4, 11 and 12)
Blueprint ProblemProcess Value Analysis and Reporting of Value- and
Nonvalue-Added Costs
Blueprint ProblemTrend Reporting of Nonvalue-added Costs and Kaizen
Costing
Blueprint ProblemActivity-based Flexible Budgeting and Activity-Capacity
Management

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