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Mercury, Inc., produces cell phones at its plant in Texas. In recent years, the company's market share has been eroded by stiff competition from overseas. Price and product quality are the two key areas in which companies compete in this market. A year ago, the company's cell phones had been ranked low in product quality in a consumer survey. Shocked by this result, Jorge Gomez, Mercury's president, initiated an intense effort to improve product quality. Gomez set up a task force to implement a formal quality improvement program. Included on this task force were representatives from the Engineering, Marketing, Customer Service, Production, and Accounting departments. The broad representation was needed because Gomez believed that this was a companywide program and that all employees should share the responsibility for its success After the first meeting of the task force, Holly Elsoe, manager of the Marketing Department, asked John Tran, production manager, what he thought of the proposed program. Tran replied, "I have reservations. Quality is too abstract to be attaching costs to it and then to be holding you and me responsible for cost improvements. I like to work with goals that I can see and count! l'm nervous about having my annual bonus based on a decrease in quality costs; there are too many variables that we have no control over." Mercury's quality improvement program has now been in operation for one year. The company's most recent quality cost report is shown below Quality Cost Report (in thousands) Last Year This Year Prevention costs: Machine maintenance Training suppliers Quality circles $370 130 10 85 225 21 400 Total prevention cost Appraisal costs: Incoming inspection Final testing 65 150 215 20 Total appraisal cost Internal failure costs: 108 Rework Scrap 110 74 184 70 45 115 Total internal failure cost External failure costs: Warranty repairs 78 252 330 28 87 Customer returns Total external failure cost Total quality cost Total production cost s 1,129 563 $4,270 4,670 As they were reviewing the report, Elsoe asked Tran what he now thought of the quality improvement program. Tran replied. "l'm relieved that the new quality improvement program hasn't hurt our bonuses, but the program has increased the workload in the Production Department. It is true that customer returns are way down, but the cell phones that were returned by customers to retail outlets were rarely sent back to us for rework." Required: 1. Expand the company's quality cost report by showing the costs in both years as y cost. (Round your percentage answers to 1 decimal place (i.e 0.1234 should be entered as 12.3).) Mercury, Inc Quality Cost Report (in thousands) Last Year This Year Percentage of Total Production Cost Percentage of Total Quality Cost Percentage of Total Production Percentageof Total Quality Cost Amount Amount Cost Prevention costs Machine maintenance Training suppliers Quality circles $ 130 10 85 225 370 21 400 Total prevention costs Appraisal costs Incoming inspection Final testing 65 150 215 20 Total appraisal costs Internal failure costs: 108 110 74 184 70 45 115 Rework Scrap Total internal failure costs External failure costs: Warranty repairs Customer returns Total external failure costs Total quality cost Total production cost 78 252 330 $1,129 28 87 115 563 $4,670 4,270
