Standard Costing in Kaizen
Standard Costing in Kaizen
Standard Costing in Kaizen
Budgetary Control
1. Objectives
2. Methods
3. Advantages of Budgetary Control
4. Problems
5. Characteristics
6. Administration
7. Budget Preparation
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1. Common Principles
2. System Differences
3. Overview
4. Applicability
5. Period
4
Management Control
1. Variance Analysis
2. Management by Exception
3. Application in different organizations
4. Standard Cost & Behavioral Issue
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Management Control
1. Variance Analysis
2. Management by Exception
3. Application in different organizations
4. Standard Cost & Behavioral Issue
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Management Control
1. Variance Analysis
2. Management by Exception
3. Application in different organizations
4. Standard Cost & Behavioral Issue
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Management Control
1. Variance Analysis
2. Management by Exception
3. Application in different organizations
4. Standard Cost & Behavioral Issue
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Marginal costing
PRS
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Example
Profit Reconciliation Statement
$ $ $
Budgeted profit 14000
Sales variances
Sales margin price 8000 F
Sales margin volume 3400 A 4600 F
Materials cost variance
Materials price 480 A
Material usage 2400 F 1920 F
Labour cost variance
Labour rate 3200 A
Labour efficiency 4000 A 7200 A
Variable overhead variance
VO Expenditure 900 F
VO Efficiency 1600 A 700 A
Fixed overhead expenditure variance 400F 980 A
Actual profit 13020
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Absorption costing
PRS
13
Example
Profit Reconciliation Statement
Budgeted profit 14000
Sales variances
Sales margin price 8000 F
Sales margin volume 2800 A 5200 F
Materials cost variance
Materials price 480 A
Material usage 2400 F 1920 F
Labour cost variance
Labour rate 3200 A
Labour efficiency 4000 A 7200 A
Variable overhead variance
VO Expenditure 900 F
VO Efficiency 1600 A 700 A
Fixed overhead variance
FO expenditure 400F
FO Volume 600 A 200 A 980 A
Actual profit 13020
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Types of Standards
1. Ideal standards are standards that demand maximum
efficiency.
Disposition of variances
Disposition of Materials and Labor Variances:
Kaizen Costing
• Kaizen costing is a cost-reduction system that is
applied to a product in production.
Kaizen Costing
• Some of the cost-reduction strategies employed
involve producing cheaper re-designs, eliminating
waste and reducing process costs. Ensuring quality
control, using more efficient equipment, utilizing
new technological advances and standardizing work
are additional elements.
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Kaizen Costing
• Kaizen costing is variant of standard costing.
Standard costing specifies a cost target for the
production team for the coming period. Normally
standard cost is set for an year. It will be revised
every year. It is constant for an year as a planning
device. Any variances from it are examined and the
reasons are identified and understood.
Evolution of Kaizen
• The Japanese implemented this cost reduction philosophy
in a systematic and objective manner. They made planned
reductions in the standard costs of an item every year. So
the production and sales team have to plan their
department and activity cost to achieve reduction in
standard cost. The idea was extended by them to monthly
costs.
• Such a reducing cost target for every month demands
some effort on cost reduction by departments every
month. Hence cost reduction is on the monthly agenda of
every department in the company. Kaizen costing is
providing the monthly cost target information and
accounting for actuals during the month.
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Kaizen method
For a Japanese firm that uses target costing, a new
product project is established when a new product is
proposed. The actual costing system is implemented
during the initial design stage. There are 6 plans
involved in the product process:
• Plan 1 – Production, Distribution, and Sales Plan
(which includes projections of contribution margins
from sales).
• Plan 2 – Projected Parts and Materials Costs.
• Plan 3 – Plant Rationalization Plan (projected
reductions in manufacturing variable costs).
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Continuous improvement
• Standard costs are steadily reduced by
continuous improvement efforts towards the target
cost. While the target cost is established during
the design stage, standard costs (as well as other
cost reduction techniques) are used during the
production stage to attain the target cost. Thus,
the standard costing system tracks progress in
achieving the target cost.
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Continuous improvement
• Cost reduction techniques include standard
costing. However, standard costing has limited
applicability and can lead to undesirable results.
For example, to minimize the purchase price
variance, a purchasing manager may purchase a
cheaper, lower quality part.
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Continuous improvement
• As a result, the quality of the product is likely to be
reduced, and the company may experience higher
overall costs in the form of rework or warranty
problems.
• In contrast, Kaizen costing is performed on a
company-wide basis and can be used in planning,
design, and other processes as well as production.
Kaizen costing activities do not reduce the overall
quality of the product; they do ensure that
expenditures result in the receipt of appropriate
value.
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Comparison
Comparison
Standard Cost Techniques
• Standards are set annually or semiannually.
• Cost variance analysis involving standard costs
and actual costs.
• Investigate and respond when standards are not met.
Performance Management
• CIMA defines standard costing as “a control technique
that reports variances by comparing actual costs to
preset standards facilitating action through management
by exception”.
• The main aim of this cost-control tool is to avoid adverse
variances, based on the assumption that manufacturing
conditions will not change. Standards are usually set
before the year to which they relate and do not change
for the whole period, unless a major cost or change in
circumstances renders them obsolete. Kaizen cost
targets, on the other hand, are usually set monthly.
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Performance Management
STANDARD COSTING –
CHALLENGES IN
IMPLEMENTATION IN TODAY'S
MANUFACTURING ENVIRONMENT
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Emerging issues
Standard setting
• The scientific management engineers divided the
production system into a number of simple repetitive tasks
in order to obtain the advantages of specialisation and to
eliminate the time wasted by workers changing from one
task to another.
• Once individual tasks and methods have been clearly
defined it is a relatively simple matter to set standards of
performance using work study and time and motion study.
These standards of performance then serve as the basis
for financial control: monetary values are assigned to both
standards and deviations from standard, i.e. variances.
These variances are then attributed to particular
operations/ responsibility centres.
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Business Environment
• Companies operating in today's manufacturing
environment, however, are likely to have strategies based
on objectives such as improving quality, increasing
flexibility to meet customers' individual requirements,
reducing manufacturing lead times and delivery times,
reducing inventories and unit costs.
• To help achieve these objectives, manufacturing
strategies such as just-in-time (JIT), advanced
manufacturing technology (AMT) and continuous
improvement are often applied. Kaplan and others argue
that standard costing is counter-productive in such an
environment.
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FO Volume variance
• The fixed overhead volume variance arises as a result of a
given level of overhead expenditure being spread over a
different number of units from the number budgeted.
Adjusting output downwards to meet a fall in short-term
demand will, however, mean fewer units to absorb the fixed
overhead, resulting in an adverse volume variance.
JIT
• In a JIT/AMT/continuous improvement environment, the
workforce is usually, organised into empowered, multi-
skilled teams controlling operations autonomously
• The feedback they require is real time and in physical
terms. Periodic financial variance reports are neither
meaningful nor timely enough to facilitate appropriate
control action.
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TQM
• In a total quality management (TQM) environment,
standard costing variance measurement places an
emphasis on cost control to the likely detriment of quality
• TQM requires a total managerial and worker ethos of
improving and maintaining quality, and of resolving
problems relating to this.
• The emphasis of standard costing is on cost control;
variance analysis is likely to pull managerial and worker
interest away from perhaps critical quality issues. Thus
cost control may be achieved at the expense of quality
and competitive advantage.
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• Net Sales
• Overtime
• Material Cost
• Supplies
• Gross Margin
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Lean Accounting
V/s
Standard Costing
• Focus & Approach
• Process Control
• Operational Differences
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Transformation to Lean
Accounting System
• 5 Steps process
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Standard Costing
Corporate Insights
Standard Costing
• Future Role
• Transformation in approach
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Way forward
• The basic principle of accounting control embodied in
standard costing remains sound. The constituents of the
standard, the variances calculated and the way they are
interpreted may need to change.
Recap
• SC Concepts
• Budgetary Control
• RM, L, OH, S
• Variance Analysis
• Kaizen
• Quality Variance
• Lean Accounting
• Software
• Survey
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4. If the direct labor force is poorly trained, which of the following variances is
most likely to occur?
a. unfavorable direct labor efficiency variance
b. unfavorable direct labor rate variance
c. favorable direct materials efficiency variance
d. favorable fixed overhead spending variance
e. unfavorable variable overhead spending variance
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10. Assume the same information as in Question 9 above. The direct materials
usage variance is:
a. $2,000 unfavorable.
b. $2,400 favorable.
c. $7,600 unfavorable.
d. $9,600 unfavorable.
e. none of the above.
Please Note: “Favorable” Variances May
Be Unfavorable
Thank You