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TufStuff, Incorporated, sells a wide range of drums, bins, boxes, and other containers that are used in the chemical Industry. One of the company's products
TufStuff, Incorporated, sells a wide range of drums, bins, boxes, and other containers that are used in the chemical Industry. One of the company's products is a heavy-duty corrosion-resistant metal drum, called the WVD drum, used to store toxlc wastes. Production is constrained by the capacity of an automated welding machine that is used to make precislon welds. A total of 2,060 hours of welding time is avallable annually on the machine. Because each drum requires 0.4 hours of weiding machine time, annual production is limited to 5,150 drums. At present, the welding machine is used exclusively to make the WVD drums. The accounting department has provided the following financlal data concerning the WVD drums: Management belleves 6,075 WVD drums could be sold each year If the company had sufficlent manufacturing capacity. As an alternative to adding another weiding machine, management has considered buyling additional drums from an outside supplier. Harcor Industrles, Incorporated, a supplier of quality products, would be able to provide up to 4,150 WVD-type drums per year at a price of \$147 per drum, which TufStuff would resell to its customers at its normal selling price after approprlate relabeling. Megan Flores, Tuf'Stuff's production manager, has suggested that the company could make better use of the welding machine by manufacturing bike frames, which would require only 0.5 hours of welding machine time per frame and yet sell for far more than the drums. Megan believes that TufStuff could sell up to 1,660 bike frames per year to bike manufacturers at a price of $254 each. The accounting department has provided the following data concerning the proposed new product: The bike frames could be produced with existing equipment and personnel. Manufacturing overhead is allocated to products on the basis of direct labor-hours. Most of the manufacturing overhead consists of fixed common costs such as rent on the factory building. but some of It is varlable. The varlable manufacturing overhead has been estimated at $1.35 per WVD drum and $1.90 per bike frame. The varlable manufacturing overhead cost would not be Incurred on drums acquilred from the outside supplier. Selling and administrative expenses are allocated to products on the basis of revenues. Almost all of the selling and administrative expenses are fixed common costs, but it has been estimated that varlable selling and administrative expenses amount to $.75 per WVD drum whether made or purchased and would be $1.60 per bike frame. All of the company's employees_direct and indirect-are pald for full 40.00-hour work weeks and the company has a policy of layling off workers only In major recessions. As soon as your analysis was shown to the top management team at TufStuff, several managers got into an argument concerning how direct labor costs should be treated when making this decision. One manager argued that direct labor is always treated as a varlable cost in textbooks and In practice and has always been considered a varlable cost at TufStuff. After all, "direct" means you can directly trace the cost to products. "If direct labor is not a varlable cost, what is?" Another manager argued just as strenuously that direct labor should be considered a fixed cost at TufStuff. No one had been laid off In over a decade, and for all practlcal purposes, everyone at the plant is on a monthly salary. Everyone classlfied as direct labor works a regular 40.00-hour workweek and overtime has not been necessary since the company adopted Lean Production techniques. Whether the welding machine is used to make drums or frames, the total payroll would be exactly the same. There is enough slack, In the form of Idle time, to accommodate any increase In total direct labor time that the bike frames would require. Required: 1. Would you be comfortable relying on the financlal data provided by the accounting department for making decisions related to the WVD drums and bike frames? 2. Compute the contribution margin per unit. [assume direct labor is a fixed cost] 3. Compute the contribution margin per welding hour. [assume direct labor is a fixed cost] 4. Assuming direct labor is a fixed cost: a. Determine the number of WVD drums (If any) that should be purchased and the number of WVD drums and/or bike frames (If any) that should be manufactured. b. What is the Increase (decrease) In net operating Income that would result from this plan over current operations? 5. Compute the contribution margin per unit. [assume direct labor is a varlable cost] 6. Compute the contribution margin per welding hour. [assume direct labor is a varlable cost] 7. Assuming direct labor is a varlable cost: a. Determine the number of WVD drums (If any) that should be purchased and the number of WVD drums and/or bike frames (If any) that should be manufactured. b. What is the Increase (decrease) In net operating income that would result from this plan over current operations
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