Exercise 12.12 (Algorithmic) Value-Added and Non-Value-Added Costs, Unused Capacity

For Situations 1 through 6, provide the following information:

An estimate of the non-value-added cost caused by each activity. If required, round your final answer to the nearest dollar. The root causes of the activity cost (such as plant layout, process design, and product design). The appropriate cost reduction measure: activity elimination, activity reduction, activity sharing, or activity selection.

Choose " Multiple" in the Root cause column, wherever there is more than one root cause.

It takes 39 minutes and fifteen pounds of material to produce a product using a traditional manufacturing process. A process reengineering study provided a new manufacturing process design (using existing technology) that would take 9 minutes and 10 pounds of material. The cost per labor hour is $14, and the cost per pound of material is $12. With its original design, a product requires 11 hours of setup time. Redesigning the product could reduce the setup time to an absolute minimum of 22 minutes. The cost per hour of setup time is $120. A product currently requires eleven moves. By redesigning the manufacturing layout, the number of moves can be reduced from eleven to zero. The cost per move is $10. Inspection time for a plant is 8,000 hours per year. The cost of inspection consists of salaries of four inspectors, totaling $100,000. Inspection also uses supplies costing $23 per inspection hour. A supplier evaluation program, product redesign, and process redesign reduced the need for inspection by creating a zero-defect environment. Each unit of a product requires sixteen components. The average number of components is 16.3 due to component failure, requiring rework and extra components. By developing relations with the right suppliers and increasing the quality of the purchased component, the average number of components can be reduced to 16 components per unit. The cost per component is $300. A plant produces 500 different electronic products. Each product requires an average of 28 components that are purchased externally. The components are different for each part. By redesigning the products, it is possible to produce the 500 products so that they all have 14 components in common. This will reduce the demand for purchasing, receiving, and paying bills. Estimated savings from the reduced demand are $1,090,000 per year.

Case Non-Value-Added Cost Root Cause Cost Reduction 1 $ per unit - Select your answer - Multiple Plant layout Process design Product design Suppliers Item 2 - Select your answer - Activity elimination Activity reduction Activity selection Activity sharing Item 3 2 $ per setup - Select your answer - Multiple Plant layout Process design Product design Suppliers Item 5 - Select your answer - Activity elimination Activity reduction Activity selection Activity sharing Item 6 3 $ per unit - Select your answer - Multiple Plant layout Process design Product design Suppliers Item 8 - Select your answer - Activity elimination Activity reduction Activity selection Activity sharing Item 9 4 $ per year - Select your answer - Multiple Plant layout Process design Product design Suppliers Item 11 - Select your answer - Activity elimination Activity reduction Activity selection Activity sharing Item 12 5 $ per unit - Select your answer - Multiple Plant layout Process design Product design Suppliers Item 14 - Select your answer - Activity elimination Activity reduction Activity selection Activity sharing Item 15 6 $ per year - Select your answer - Multiple Plant layout Process design Product design Suppliers Item 17 - Select your answer - Activity elimination Activity reduction Activity selection Activity sharing Item 18