This document discusses implementing an activity-based costing (ABC) system at a Taiwanese semiconductor process equipment factory (SPEF) to more accurately estimate product costs. Currently, the SPEF uses a traditional costing system that does not precisely reflect production costs. The ABC system would assign costs to products based on the activities and resources required to produce them. An analysis of the SPEF's current cost structure is provided. The document proposes developing an ABC model for the SPEF and comparing the results to the traditional system to analyze benefits and obstacles of the ABC approach.
This document proposes using Markov chains to model and analyze industrial electronic repair processes. Markov chains are well-suited for this application because repair processes are stochastic in nature, with many possible paths and outcomes. The document introduces two Markov chain models - an absorbing Markov chain model and an acyclic absorbing Markov chain model - to represent repair processes and determine important operational parameters. The models can help identify improvement opportunities, support quality control efforts, and inform resource allocation decisions. An example application to a real electronic repair process is also discussed.
Design and Implement the Activity-Based Costing in Taiwan FirmIOSRJBM
We design and implement the activity-based costing (ABC) to the communication firm in Taiwan which originally adopted the existing traditional costing method (TC) to measure the unit cost. In contemporary research, the activity-based costing (ABC) was utilized to measure and analyze the product unit cost in production process. This firm originally adopted a roughly estimate based in cost system to allocate support department cost, meanwhile it adopted the direct labor hour (DLR) to allocate the conversion costs to products. This original traditional costing (TC) has the weakness on distorting the product unit cost since it pulls all of costs into the single pool and activity. We collected and analyzed field data for 24 months through interviews, files gathering, and cost data to analyze B Company’s product characteristics, production process, and existing costing during 2010 to 2012. We compared and contrasted B firm implemented both ABC and TC cost allocation method on unit cost, the activity center and production system. Our researches focus on analyzing the existing cost accounting system, designing a practical ABC system and applying ABC on the support-cost allocation, comparing the cost data under the existing cost system and ABC, and providing the suggestion about the ABC implementation follow-up activities.Our results found that the traditional cost system in this firm overestimates the costs of high direct labor-hour products and underestimates the costs of high complexity products. Instead of the tradition costing (TC) or the conventional costing or the simple costing with the single indirect-cost pool and arbitrary allocation bases, the ABC creates homogeneous cost pools (activities) linked to different cost-allocation bases that have cause-and-effect relationships. Finally, our findings are that the implementation of the ABC provided more accuracy in allocating the unit cost, more reasonable information and cost allocation for the activity center, and non-financial information for the production system.
This article proposes a detailed calculation model for costing green manufacturing that incorporates concepts of industrial dynamics and product lifecycles. The model comprises a process-based cost model focusing on carbon emission costs and energy-saving activities, and a systems dynamics model that simulates dynamic metrics often ignored in traditional models. The findings show equipment costs and carbon emission costs are major cost components, and the total lifecycle cost of a green manufactured product is lower than a conventionally manufactured product. The model provides a tool for managers to accurately allocate resources for energy-saving activities based on appropriate cost drivers.
This document discusses the development of a casting cost estimation model to help product designers estimate costs early in the design process. The model is driven by the part's solid model, material, geometry, quality and production requirements. Analytical equations estimate material and conversion costs, while a parametric model estimates tooling costs based on part complexity computed from the solid model. Process planning and methoding programs generate parameters for accurate cost estimation and link to a collaborative engineering system for data sharing. An industrial example illustrates the entire system.
The proposed approach involves two stages to estimate product costs using historical data. In the preparatory stage, standard routings are extracted from past products and a generic activity hierarchy is established. Time-estimating relationships are determined by analyzing standard times. Cost-estimating relationships are set by allocating overhead costs. In the production stage, cost-related design features are induced from a new design to estimate a standard time using the relationships. Total product cost is then compiled using material costs and cost-estimating relationships. This allows for rapid cost estimation early in the design process using a common time measurement without detailed design or manufacturing knowledge.
Developing the Tool for Vendor Selection in Power Sector using Cost of QualityIRJET Journal
This document discusses developing a tool for vendor selection in the power sector using cost of quality analysis. It presents a case study of Tata Power Delhi Distribution Ltd., which aims to integrate supplier historical quality performance data into future supplier selections. The researchers conducted interviews and analyzed documentation to identify key cost drivers related to quality issues. They developed a supplier quality performance tool that calculates total cost of quality for suppliers based on specific cost drivers. This total cost is then added to the purchase price to evaluate suppliers. The case study focuses on distribution transformer rejections and failures at Tata Power, estimating related quality costs. The goal is to help the company make more informed supplier selections factoring in total cost of quality.
Developing the Tool for Vendor Selection in Power Sector using Cost of QualityIRJET Journal
This document discusses developing a tool for vendor selection in the power sector using cost of quality analysis. It presents a case study of Tata Power Delhi Distribution Ltd., which aims to integrate supplier historical quality performance data into future supplier selections. The researchers conducted interviews and analyzed documentation to identify key cost drivers related to quality issues. They developed a supplier quality performance tool that calculates total cost of quality for suppliers based on specific cost drivers. This total cost is then added to the purchase price to evaluate suppliers. The case study focuses on distribution transformer rejections and failures at Tata Power, estimating related quality costs. The goal is to help the company make more informed supplier selections factoring in total cost of quality.
This document proposes using Markov chains to model and analyze industrial electronic repair processes. Markov chains are well-suited for this application because repair processes are stochastic in nature, with many possible paths and outcomes. The document introduces two Markov chain models - an absorbing Markov chain model and an acyclic absorbing Markov chain model - to represent repair processes and determine important operational parameters. The models can help identify improvement opportunities, support quality control efforts, and inform resource allocation decisions. An example application to a real electronic repair process is also discussed.
Design and Implement the Activity-Based Costing in Taiwan FirmIOSRJBM
We design and implement the activity-based costing (ABC) to the communication firm in Taiwan which originally adopted the existing traditional costing method (TC) to measure the unit cost. In contemporary research, the activity-based costing (ABC) was utilized to measure and analyze the product unit cost in production process. This firm originally adopted a roughly estimate based in cost system to allocate support department cost, meanwhile it adopted the direct labor hour (DLR) to allocate the conversion costs to products. This original traditional costing (TC) has the weakness on distorting the product unit cost since it pulls all of costs into the single pool and activity. We collected and analyzed field data for 24 months through interviews, files gathering, and cost data to analyze B Company’s product characteristics, production process, and existing costing during 2010 to 2012. We compared and contrasted B firm implemented both ABC and TC cost allocation method on unit cost, the activity center and production system. Our researches focus on analyzing the existing cost accounting system, designing a practical ABC system and applying ABC on the support-cost allocation, comparing the cost data under the existing cost system and ABC, and providing the suggestion about the ABC implementation follow-up activities.Our results found that the traditional cost system in this firm overestimates the costs of high direct labor-hour products and underestimates the costs of high complexity products. Instead of the tradition costing (TC) or the conventional costing or the simple costing with the single indirect-cost pool and arbitrary allocation bases, the ABC creates homogeneous cost pools (activities) linked to different cost-allocation bases that have cause-and-effect relationships. Finally, our findings are that the implementation of the ABC provided more accuracy in allocating the unit cost, more reasonable information and cost allocation for the activity center, and non-financial information for the production system.
This article proposes a detailed calculation model for costing green manufacturing that incorporates concepts of industrial dynamics and product lifecycles. The model comprises a process-based cost model focusing on carbon emission costs and energy-saving activities, and a systems dynamics model that simulates dynamic metrics often ignored in traditional models. The findings show equipment costs and carbon emission costs are major cost components, and the total lifecycle cost of a green manufactured product is lower than a conventionally manufactured product. The model provides a tool for managers to accurately allocate resources for energy-saving activities based on appropriate cost drivers.
This document discusses the development of a casting cost estimation model to help product designers estimate costs early in the design process. The model is driven by the part's solid model, material, geometry, quality and production requirements. Analytical equations estimate material and conversion costs, while a parametric model estimates tooling costs based on part complexity computed from the solid model. Process planning and methoding programs generate parameters for accurate cost estimation and link to a collaborative engineering system for data sharing. An industrial example illustrates the entire system.
The proposed approach involves two stages to estimate product costs using historical data. In the preparatory stage, standard routings are extracted from past products and a generic activity hierarchy is established. Time-estimating relationships are determined by analyzing standard times. Cost-estimating relationships are set by allocating overhead costs. In the production stage, cost-related design features are induced from a new design to estimate a standard time using the relationships. Total product cost is then compiled using material costs and cost-estimating relationships. This allows for rapid cost estimation early in the design process using a common time measurement without detailed design or manufacturing knowledge.
Developing the Tool for Vendor Selection in Power Sector using Cost of QualityIRJET Journal
This document discusses developing a tool for vendor selection in the power sector using cost of quality analysis. It presents a case study of Tata Power Delhi Distribution Ltd., which aims to integrate supplier historical quality performance data into future supplier selections. The researchers conducted interviews and analyzed documentation to identify key cost drivers related to quality issues. They developed a supplier quality performance tool that calculates total cost of quality for suppliers based on specific cost drivers. This total cost is then added to the purchase price to evaluate suppliers. The case study focuses on distribution transformer rejections and failures at Tata Power, estimating related quality costs. The goal is to help the company make more informed supplier selections factoring in total cost of quality.
Developing the Tool for Vendor Selection in Power Sector using Cost of QualityIRJET Journal
This document discusses developing a tool for vendor selection in the power sector using cost of quality analysis. It presents a case study of Tata Power Delhi Distribution Ltd., which aims to integrate supplier historical quality performance data into future supplier selections. The researchers conducted interviews and analyzed documentation to identify key cost drivers related to quality issues. They developed a supplier quality performance tool that calculates total cost of quality for suppliers based on specific cost drivers. This total cost is then added to the purchase price to evaluate suppliers. The case study focuses on distribution transformer rejections and failures at Tata Power, estimating related quality costs. The goal is to help the company make more informed supplier selections factoring in total cost of quality.
Improving Supply Chain Activity using Simulationijsrd.com
The discovery through computational modeling and simulation has become the third pillar of science, alongside theory and experimentation. As computational power increases, simulation has gained in importance and has become a major research area, where highly parallel computation is utilized. In this dissertation, we have performed the simulation by selecting a single machine which is involved in manufacturing the highest number of products. Data are collected for all the processes involved in the manufacturing processes and an input modelling analysis is been done for the data collected. After the analysis is completed, a simulation model is constructed using ARENA which involved all the manufacturing process using the simulation tools. With the help of the simulation tools we will be able to identify activities causing the bottlenecks and delays in the entire manufacturing processes. Similarly, this simulation can be carried out for each and every machine of the company so that we can identify the bottlenecks and delays. As a result, the bottlenecks and delays can be reduced and the entire supply chain can be improved. This paper aims at combining supply chain management and simulation - to give an overview of both areas and shows how supply chain management can profit from simulation and also to identify the delays and bottlenecks in the overall manufacturing process. Lastly, a sample of how a supply chain can be optimized, in the simulation development suite ARENA.
Modelling Production Performance of Small Scale Production PlantIJAEMSJORNAL
This document presents a study that developed a model to evaluate capacity utilization (CU) of small-scale production plants. The model considers key inputs like plant operators, capital, research and development spending, energy usage, and machinery maintenance expenditures. The dependent variable is CU of the plant. The model is tested on a small-scale water production plant. Results show the plant's average CU was 74% over six months. All inputs were positively correlated to CU, with major inputs significantly contributing to it. The model explained about 80% of CU with inputs. The model's estimated outputs were within 2% of actual recorded outputs. The model was found to be statistically significant and useful for small-scale plants to evaluate production performance.
IRJET- Value Engineering: Better Way of Implementing Conventional MethodsIRJET Journal
This document discusses value engineering and its application in various fields. It begins with an introduction to value engineering, defining it as a creative, organized effort to analyze projects to achieve essential functions cost-effectively. It then provides examples of value engineering being used in waste management, residual value analysis of vehicles, and machine-based optimization. The document concludes that value engineering can reduce production costs through techniques like reducing cycle times, optimizing materials and weights, and improving product life cycles and sustainable development.
This document summarizes a study on implementing value stream mapping in a manufacturing industry. The study was conducted at a CNC machining center division to reduce cycle times and eliminate waste. Current state value stream maps were created for main components to identify issues. The maps found processes that could be outsourced and ways to reduce setup and cycle times. A future state map was proposed for one component. The literature review discussed previous research on using value stream mapping as a lean tool to visualize flows, reduce waste, and improve processes.
Improvement of Productivity Using Value Stream Mappingijsrd.com
one of the most appropriate ways to emerge the productivity for the particular area is through Lean Manufacturing. Value stream mapping is that lean manufacturing tool which helps to improve the productivity for the area through its detailed mapping. It is the visualize tool which describes the current state map followed by lean techniques resulting into the final state map that aiming at reduction of the non-value added activities throughout its phase. This paper illustrates the review of VSM techniques and its benefits in machining industry. The purpose of this paper is to highlight the effective utilization of the VSM tools for process and productivity improvements.
A genetic algorithm approach for multi objective optimization of supply chain...Phuong Dx
This document summarizes a research paper that proposes using a genetic algorithm to solve a multi-objective supply chain network design problem. The objectives are to minimize total costs, maximize customer service levels, and maximize balanced capacity utilization across distribution centers. An experiment is conducted using real company data to evaluate the performance of the genetic algorithm and compare it to multi-objective simulated annealing. The genetic algorithm is able to generate a set of Pareto-optimal solutions for the decision maker to evaluate tradeoffs between multiple conflicting objectives in supply chain network design.
This document presents a case study comparing activity-based costing (ABC) and traditional costing methods at a Turkish sanitaryware company. The company produces products through bulk preparation, pressing, classical casting, glazing, and final packaging processes. Time sheets were used to identify activities and associated resource usage. Labor costs were then assigned to activities based on time spent. This allowed calculating product costs based on each product's use of activities, providing more accurate costs than traditional costing. The ABC analysis highlighted weaknesses in traditional costing and identified undercosted and overcosted products.
The document discusses the economic surplus model, which is a tool used for ex-ante impact assessment. It provides an overview of the concept, assumptions, specifications, data requirements, and computation of the economic surplus model. The model is popular because it requires relatively little data and provides reliable results. While it has merits such as estimating distribution of benefits, it also has limitations like ignoring transaction costs. The document examines case studies applying the model to assess potential impacts of Bt brinjal in India and actual impacts of a drought-resistant groundnut variety in Andhra Pradesh.
The document discusses the economic surplus model, which is a tool used for ex-ante impact assessment. It provides an overview of the concept, assumptions, specifications, data requirements, and computation of the economic surplus model. The model is popular because it requires relatively little data and provides reliable results. While it has merits such as estimating distribution of benefits, it also has limitations like ignoring transaction costs. The document examines case studies applying the model to assess potential impacts of Bt brinjal in India and actual impacts of a drought-resistant groundnut variety in Andhra Pradesh.
IRJET- Enhance the Capacity of Outer Tube Machining CellIRJET Journal
This document discusses enhancing the capacity of an outer tube machining cell at a manufacturing plant. It begins by outlining the current problem of not being able to meet customer demand and having a production gap. The objectives are then stated as increasing production rate, maximizing resource use, meeting customer requirements, and increasing profit. Data is collected from the shop floor on processing times for each workstation. The longest processing workstation is identified as the bottleneck. Modifications are proposed to reduce processing time at the bottleneck station, such as modifying a scrap fixture, in order to increase production rate and meet forecasted demand. The proposed changes are expected to increase the production rate and fulfill customer requirements while gaining higher profits.
Behavioral Aspects of IT Employees towards Problems and Prospects of Activity...Dr. Amarjeet Singh
Activity Based Costing (ABC) is a new variant in cost
management practices emerged in 1980’s, which caters to the
needs of organizations in effective control and monitoring cost
and better management of profitability. The success of ABC
duly depends on articulation of implementation of ABC and
the outcome of Activity Based Cost and Management
(ABCM). Though employees experience a positive outcome, it
is beyond doubt that they can support the ABC rather
resisting the same. The main objective of this paper is to
examine the perception of IT companies’ employees’ towards
implementation of Activity-Based Costing(ABC). A normative
list of benefits concerning the ability of ABC systems to
redirect the behavior of individuals was abstracted from the
interviews opinion and compared to the perceived benefits
gathered from interviews with firm employees. This will
permit IT Companies and provides relevant information that
will enable them to make better decisions with regard to
measure the successful implementation of ABC in IT
Companies.
Multidisciplinary Journal Supported by TETFund. The journals would publish papers covering a wide range of subjects in journal science, management science, educational, agricultural, architectural, accounting and finance, business administration, entrepreneurship, business education, all journals
International Journal of Business and Management Invention (IJBMI) is an international journal intended for professionals and researchers in all fields of Business and Management. IJBMI publishes research articles and reviews within the whole field Business and Management, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
The document presents an integrated framework for estimating the costs of dies and molds. It discusses previous cost estimation methods and their limitations. The proposed method uses geometric features of the cavity and core as cost drivers to estimate basic mold costs. It also considers cost modifiers like parting lines, side cores, surface texture and materials that contribute to total mold costs. The framework was tested on 13 industrial examples with an average deviation of 0.40%. It provides a flexible way to customize cost modifiers and estimate costs for different mold types.
The document proposes a new work item (NWIP) for an international standard on determining Ergonomic Work Allowance (EWA) for cyclical industrial work. It aims to standardize how recovery periods are set to control biomechanical workload in repetitive manufacturing jobs. The proposal recommends measuring work, evaluating biomechanical load using holistic methods, and using an engineered model to calculate recovery needs based on task design, workload duration and intensity, and work organization factors like shift length and break scheduling. Adopting this standard globally could improve worker health, safety, and productivity while reducing ergonomic risk assessment costs for manufacturers.
A REVIEW ON EARNED VALUE MANAGEMENT TECHNIQUES ASSURING QUALITY AND SAFETY PA...IRJET Journal
This document provides a review of Earned Value Management (EVM) techniques for assuring quality and safety during and after the COVID-19 pandemic. It discusses how EVM can be enhanced to capture quality and safety metrics through a new Earned Value Construction Operations system. The document reviews literature on previous uses of EVM in construction projects and describes the key components and benefits of EVM for monitoring project schedule, cost, quality and safety performance. It also discusses best practices for estimating the number of construction workers in India and the associated costs and schedule impacts of pandemic construction using an enhanced EVM approach.
Value Engineering is a technique for determining the manufacturing requirements of a
product/service; it is concerned with its evaluation and finally the selection of less costly
conditions. VE is a process for achieving the optimal result in a way that quality, safety, reliability
and convertibility of every monetary unit are improved.
Here theory of Value Engineering along with case study of UTM is presented.
Achieving Cost Optimization via IT IntegrationOnur Tamur
IT-enabled manufacturing systems are highly valued in current business world because of the benefits they provide in process optimization and cost reduction and these systems are increasing their dominance in the industrial markets thanks to the continuous technological improvements in IT sector. Even though automation systems require high amount of capital investment, they usually pay back in a short period of time depending on the values enabled to their users. Thus, major firms are eager to adopt automated systems in their manufacturing facilities to able to benefit from these opportunities and guarantee steady growth.
This study is started by the case study of Sel Hoses in collaboration with Tampere University of Technology. Sel Hoses is a Turkish hose manufacturer that is one of the biggest suppliers of industrial hoses to European markets and recognized as a high quality and low cost manufacturer. The industry is eager to adopt automated cutting process in their manufacturing plants to lower labour costs and optimize the cutting process by lowering the waste of hoses and Sel Hoses will play a key role in this implementation if they launch the barcode system on their hose reels. Thus, the objective of this research is understand the waste reduction opportunities in hose cutting process by using PC controlled systems and how this project can be undertaken by following a hand-on approach within the value network to increase the overall value generated by the major project stakeholders.
The paper gives an insight into different theories that are applied to understand the cost dynamics of the industry and evaluate the investment decision in terms of the beneficial return. The above mentioned theories combined with extensive brainstorming with industry leaders provide managers a helpful tool to evaluate the long term growth potential of the industry and follow a collaborative strategy to bring value to the whole business network. Hence, this research attempts to identify the waste reduction possibilities in hose cutting process by using automated systems which will lead to lower material costs and process optimization.
The document outlines 5 steps for ordering an essay writing service from HelpWriting.net, including creating an account, providing assignment details in an order form, choosing a writer based on bids and qualifications, reviewing and authorizing payment for the completed paper, and having the option to request revisions. The process is described as quick, simple, and focused on ensuring customer satisfaction through original, high-quality work or a full refund.
Writing A Research Paper For Scholarly JournalsKelly Lipiec
1. The document provides instructions for writing a research paper for scholarly journals through a 5 step process. It details how to create an account, submit a request for paper writing help including instructions and sources, review writer bids and select one, authorize payment upon receiving a satisfactory paper, and request revisions if needed.
2. The second document is the beginning of a paper on hemophilia and unexpected bleeding during surgery. It discusses hemophilia pathology, risk factors, signs and symptoms, and treatment. It provides details on the anatomy and physiology of hemostasis and the coagulation cascade.
3. The third document continues the beginning of the paper, discussing how industrialization and the invention of the automobile contributed to increased greenhouse
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Improving Supply Chain Activity using Simulationijsrd.com
The discovery through computational modeling and simulation has become the third pillar of science, alongside theory and experimentation. As computational power increases, simulation has gained in importance and has become a major research area, where highly parallel computation is utilized. In this dissertation, we have performed the simulation by selecting a single machine which is involved in manufacturing the highest number of products. Data are collected for all the processes involved in the manufacturing processes and an input modelling analysis is been done for the data collected. After the analysis is completed, a simulation model is constructed using ARENA which involved all the manufacturing process using the simulation tools. With the help of the simulation tools we will be able to identify activities causing the bottlenecks and delays in the entire manufacturing processes. Similarly, this simulation can be carried out for each and every machine of the company so that we can identify the bottlenecks and delays. As a result, the bottlenecks and delays can be reduced and the entire supply chain can be improved. This paper aims at combining supply chain management and simulation - to give an overview of both areas and shows how supply chain management can profit from simulation and also to identify the delays and bottlenecks in the overall manufacturing process. Lastly, a sample of how a supply chain can be optimized, in the simulation development suite ARENA.
Modelling Production Performance of Small Scale Production PlantIJAEMSJORNAL
This document presents a study that developed a model to evaluate capacity utilization (CU) of small-scale production plants. The model considers key inputs like plant operators, capital, research and development spending, energy usage, and machinery maintenance expenditures. The dependent variable is CU of the plant. The model is tested on a small-scale water production plant. Results show the plant's average CU was 74% over six months. All inputs were positively correlated to CU, with major inputs significantly contributing to it. The model explained about 80% of CU with inputs. The model's estimated outputs were within 2% of actual recorded outputs. The model was found to be statistically significant and useful for small-scale plants to evaluate production performance.
IRJET- Value Engineering: Better Way of Implementing Conventional MethodsIRJET Journal
This document discusses value engineering and its application in various fields. It begins with an introduction to value engineering, defining it as a creative, organized effort to analyze projects to achieve essential functions cost-effectively. It then provides examples of value engineering being used in waste management, residual value analysis of vehicles, and machine-based optimization. The document concludes that value engineering can reduce production costs through techniques like reducing cycle times, optimizing materials and weights, and improving product life cycles and sustainable development.
This document summarizes a study on implementing value stream mapping in a manufacturing industry. The study was conducted at a CNC machining center division to reduce cycle times and eliminate waste. Current state value stream maps were created for main components to identify issues. The maps found processes that could be outsourced and ways to reduce setup and cycle times. A future state map was proposed for one component. The literature review discussed previous research on using value stream mapping as a lean tool to visualize flows, reduce waste, and improve processes.
Improvement of Productivity Using Value Stream Mappingijsrd.com
one of the most appropriate ways to emerge the productivity for the particular area is through Lean Manufacturing. Value stream mapping is that lean manufacturing tool which helps to improve the productivity for the area through its detailed mapping. It is the visualize tool which describes the current state map followed by lean techniques resulting into the final state map that aiming at reduction of the non-value added activities throughout its phase. This paper illustrates the review of VSM techniques and its benefits in machining industry. The purpose of this paper is to highlight the effective utilization of the VSM tools for process and productivity improvements.
A genetic algorithm approach for multi objective optimization of supply chain...Phuong Dx
This document summarizes a research paper that proposes using a genetic algorithm to solve a multi-objective supply chain network design problem. The objectives are to minimize total costs, maximize customer service levels, and maximize balanced capacity utilization across distribution centers. An experiment is conducted using real company data to evaluate the performance of the genetic algorithm and compare it to multi-objective simulated annealing. The genetic algorithm is able to generate a set of Pareto-optimal solutions for the decision maker to evaluate tradeoffs between multiple conflicting objectives in supply chain network design.
This document presents a case study comparing activity-based costing (ABC) and traditional costing methods at a Turkish sanitaryware company. The company produces products through bulk preparation, pressing, classical casting, glazing, and final packaging processes. Time sheets were used to identify activities and associated resource usage. Labor costs were then assigned to activities based on time spent. This allowed calculating product costs based on each product's use of activities, providing more accurate costs than traditional costing. The ABC analysis highlighted weaknesses in traditional costing and identified undercosted and overcosted products.
The document discusses the economic surplus model, which is a tool used for ex-ante impact assessment. It provides an overview of the concept, assumptions, specifications, data requirements, and computation of the economic surplus model. The model is popular because it requires relatively little data and provides reliable results. While it has merits such as estimating distribution of benefits, it also has limitations like ignoring transaction costs. The document examines case studies applying the model to assess potential impacts of Bt brinjal in India and actual impacts of a drought-resistant groundnut variety in Andhra Pradesh.
The document discusses the economic surplus model, which is a tool used for ex-ante impact assessment. It provides an overview of the concept, assumptions, specifications, data requirements, and computation of the economic surplus model. The model is popular because it requires relatively little data and provides reliable results. While it has merits such as estimating distribution of benefits, it also has limitations like ignoring transaction costs. The document examines case studies applying the model to assess potential impacts of Bt brinjal in India and actual impacts of a drought-resistant groundnut variety in Andhra Pradesh.
IRJET- Enhance the Capacity of Outer Tube Machining CellIRJET Journal
This document discusses enhancing the capacity of an outer tube machining cell at a manufacturing plant. It begins by outlining the current problem of not being able to meet customer demand and having a production gap. The objectives are then stated as increasing production rate, maximizing resource use, meeting customer requirements, and increasing profit. Data is collected from the shop floor on processing times for each workstation. The longest processing workstation is identified as the bottleneck. Modifications are proposed to reduce processing time at the bottleneck station, such as modifying a scrap fixture, in order to increase production rate and meet forecasted demand. The proposed changes are expected to increase the production rate and fulfill customer requirements while gaining higher profits.
Behavioral Aspects of IT Employees towards Problems and Prospects of Activity...Dr. Amarjeet Singh
Activity Based Costing (ABC) is a new variant in cost
management practices emerged in 1980’s, which caters to the
needs of organizations in effective control and monitoring cost
and better management of profitability. The success of ABC
duly depends on articulation of implementation of ABC and
the outcome of Activity Based Cost and Management
(ABCM). Though employees experience a positive outcome, it
is beyond doubt that they can support the ABC rather
resisting the same. The main objective of this paper is to
examine the perception of IT companies’ employees’ towards
implementation of Activity-Based Costing(ABC). A normative
list of benefits concerning the ability of ABC systems to
redirect the behavior of individuals was abstracted from the
interviews opinion and compared to the perceived benefits
gathered from interviews with firm employees. This will
permit IT Companies and provides relevant information that
will enable them to make better decisions with regard to
measure the successful implementation of ABC in IT
Companies.
Multidisciplinary Journal Supported by TETFund. The journals would publish papers covering a wide range of subjects in journal science, management science, educational, agricultural, architectural, accounting and finance, business administration, entrepreneurship, business education, all journals
International Journal of Business and Management Invention (IJBMI) is an international journal intended for professionals and researchers in all fields of Business and Management. IJBMI publishes research articles and reviews within the whole field Business and Management, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
The document presents an integrated framework for estimating the costs of dies and molds. It discusses previous cost estimation methods and their limitations. The proposed method uses geometric features of the cavity and core as cost drivers to estimate basic mold costs. It also considers cost modifiers like parting lines, side cores, surface texture and materials that contribute to total mold costs. The framework was tested on 13 industrial examples with an average deviation of 0.40%. It provides a flexible way to customize cost modifiers and estimate costs for different mold types.
The document proposes a new work item (NWIP) for an international standard on determining Ergonomic Work Allowance (EWA) for cyclical industrial work. It aims to standardize how recovery periods are set to control biomechanical workload in repetitive manufacturing jobs. The proposal recommends measuring work, evaluating biomechanical load using holistic methods, and using an engineered model to calculate recovery needs based on task design, workload duration and intensity, and work organization factors like shift length and break scheduling. Adopting this standard globally could improve worker health, safety, and productivity while reducing ergonomic risk assessment costs for manufacturers.
A REVIEW ON EARNED VALUE MANAGEMENT TECHNIQUES ASSURING QUALITY AND SAFETY PA...IRJET Journal
This document provides a review of Earned Value Management (EVM) techniques for assuring quality and safety during and after the COVID-19 pandemic. It discusses how EVM can be enhanced to capture quality and safety metrics through a new Earned Value Construction Operations system. The document reviews literature on previous uses of EVM in construction projects and describes the key components and benefits of EVM for monitoring project schedule, cost, quality and safety performance. It also discusses best practices for estimating the number of construction workers in India and the associated costs and schedule impacts of pandemic construction using an enhanced EVM approach.
Value Engineering is a technique for determining the manufacturing requirements of a
product/service; it is concerned with its evaluation and finally the selection of less costly
conditions. VE is a process for achieving the optimal result in a way that quality, safety, reliability
and convertibility of every monetary unit are improved.
Here theory of Value Engineering along with case study of UTM is presented.
Achieving Cost Optimization via IT IntegrationOnur Tamur
IT-enabled manufacturing systems are highly valued in current business world because of the benefits they provide in process optimization and cost reduction and these systems are increasing their dominance in the industrial markets thanks to the continuous technological improvements in IT sector. Even though automation systems require high amount of capital investment, they usually pay back in a short period of time depending on the values enabled to their users. Thus, major firms are eager to adopt automated systems in their manufacturing facilities to able to benefit from these opportunities and guarantee steady growth.
This study is started by the case study of Sel Hoses in collaboration with Tampere University of Technology. Sel Hoses is a Turkish hose manufacturer that is one of the biggest suppliers of industrial hoses to European markets and recognized as a high quality and low cost manufacturer. The industry is eager to adopt automated cutting process in their manufacturing plants to lower labour costs and optimize the cutting process by lowering the waste of hoses and Sel Hoses will play a key role in this implementation if they launch the barcode system on their hose reels. Thus, the objective of this research is understand the waste reduction opportunities in hose cutting process by using PC controlled systems and how this project can be undertaken by following a hand-on approach within the value network to increase the overall value generated by the major project stakeholders.
The paper gives an insight into different theories that are applied to understand the cost dynamics of the industry and evaluate the investment decision in terms of the beneficial return. The above mentioned theories combined with extensive brainstorming with industry leaders provide managers a helpful tool to evaluate the long term growth potential of the industry and follow a collaborative strategy to bring value to the whole business network. Hence, this research attempts to identify the waste reduction possibilities in hose cutting process by using automated systems which will lead to lower material costs and process optimization.
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2. 446 Glo. Adv. Res. J. Manag. Bus. Stud.
processes.
Keywords: Activity-Based Costing, manufacturing cost, Semiconductor Process Equipment Factory
INTRODUCTION
Presently, the semiconductor manufacturing industry has
been growing at a moderate pace in Taiwan. Both the
OEM of semiconductor manufacturing industry outputting
value of 15,987 billion in 2012 (accounting for 73% of the
world) and IC packaging testing industry were the world’s
first. In the TSMC(Taiwan Semiconductor Manufacturing
Company) and UMC (United Microelectronics Corporation)
of semiconductor manufacturing company, there were
more than 60% of the global market share ranking the
global IC manufacturing championship(SIPO ,2012).
From this reason, the Gudeng Precision Company
(Semiconductor Process Equipment Factory, SPEF) were
benefited from the semiconductor manufacturing industry.
The process of IC chip manufacturing was mask circuit
from wafer in wafer lab. In method of oxidation, diffusion,
CVD, etch, ion implantation, the components of the
circuit on the wafer were produced. Through completion
of the wafer testing, packaging and other steps, the IC
chip will be finished (Figure 1). Because the IC circuit
design is a layered structure, A complete integrated
circuits were repeated through the step of several mask
input, graphics production, and the formation of lines. In
this research, The Gudeng Precision Company of main
production were Photo mask case and Mask package
shipping box. The IC chip was placed in the Photo mask
case for the process of transportation and storage to
maintain its cleanliness protected against air dust
pollution and electrostatic damage. Finally, The IC chip
would improve its yield under the lithography process.
The Photo mask case was made of ether ketone
thermoplastic material from Victrex plc., LTD. The Photo
mask case is used to generate from High Performance
Engineering Plastics and Specialty Compound by
Asiatech Co., LTD. Due to the expensive raw materials,
there are two reason for this research: (1)There has been
increasing concerns of rising cost during the past decade.
There are no record statics on the profit margin of the
SPEF.It is only slightly higher compared to other
manufacturing industries.
The traditional cost of the product is divided into direct
materials (such as wafers), direct labors (for example, the
production line operator) and manufacturing costs (such
as depreciation, utilities, rent, etc.). The cost of direct
materials and direct labors can be directly attributable to
individual products. The manufacturing cost is based on a
simple ratio allocated to the product. Under the rapid
progress of semiconductor manufacturing technology,
The more wafer process (such as 6-inch, 8-inch,
12-inch ) is complex, the more cost of the products is
sophisticated. The cost of the product has been distorted.
Surprisingly, there has been no formal methodology for
estimating the product costs in the SPEF in Taiwan. As a
result, the actual product costs are unknown. The
management specifies the product costs and selling
prices of each product based on their experience and
competitor’s strategies. The factory would change the
prices of the products often to compete with its
competitors. Therefore, a more accurate costing system is
3. needed for estimating product costs in this industry.
Activity-based costing (ABC) is an accounting technique
that allows an organization to assign costs to products
based on the resources they consume. It recognizes the
causal relationship between cost drivers and cost
activities by measuring the cost and performance of
process-related activities and cost objects
(MacArthur,1996).ABC has been implemented
successfully in various service and manufacturing
industries. In the major book manufacturing firm, this
industry can effectively apply cost to activities of the
planning process for each individual job as a direct cost,
rather than an indirect one(Walker et al,2000). The ABC
measurement which can measure the treatment activities
more precisely(Tsai and Hung,2009) The main motivation
for a company to implement ABC is the need for reliable
cost information.Cost accounting literature has argued
that traditional cost accounting systems are obsolete in a
new environment characterized by modern production
technology; ABC has been offered as a solution (Cooper
& Kaplan,1991) . ABC systems differ from traditional
costing systems in how they are able to model the use of
all resources in all the activities performed by these
resources, and then link the cost of these activities to
products (Hundal,1997;Park &Simpson,2008). In the ABC
system, costs are traced by activities across departments
or cost centers(Cao et al, 2006;Lin et al, 2007). ABC
provides information about a product’s cost based on the
resources used in its production(Kee & Matherly,2003).
The causal relationship between products and customers
that consume resources is determined by tracing the cost
of the factor (cost driver) that is caused by (or correlates
highly with) a product’s or customer’s use of an activity’s
resources(Kee & Schmidt, 2007) . Traditional cost
accounting methods do not accurately reflect the
Chien-Lung and Chun-Hao, 447
contributions of indirect costs to individual activities.
Instead, they pool all indirect costs and allocate them to
various products (services) in proportion to product
(service) volume or direct costs( Kee, 1995). ABC solves
this problem by estimating the cost of the activities that
consume resources and by linking these costs to the
products (services) that are provided(Cao et al, 2006;Lin
et al, 2007). ABC products provides a better estimate of
product cost as well as the cost of the individual activities
used in its production (Kee, 1995). Surveys and
interviews with managers who use ABC indicate that it is
used to support a wide range of economic activities, such
as environmental management (Tsai et al, 2009) and
other activities in the environmental field. A detailed cost
assignment view of ABC is shown in Figure. 2 (Tsai,2010).
ABC focuses on the accurate cost assignment of
overheads to products. In the cost assignment view, the
assignment of costs through the ABC method occurs in
two stages: At the first stage, resource costs are assigned
to various activities by creating resource drivers. Each
type of resource traced to an activity becomes a cost
element of an activity cost pool. An activity cost pool
therefore represents the total costs identified with an
activity or activity center, which is usually clustered by
function or process. At the second stage, the costs in
each activity cost pool are allocated to cost objects by an
activity driver which is used to measure the consumption
of activities by the cost objects.
Previous studies have shown the feasibility of using the
ABC in both service and manufacturing environments
(Helmi,1991). However, most of the studies discussed
benefits and implementation of the ABC in general. Only a
few of these studies use real cost data to examine the
difference between the ABC and the traditional costing
system in a manufacturing environment. Furthermore,
4. 448 Glo. Adv. Res. J. Manag. Bus. Stud.
Figure 1. Taiwan's semiconductor industry structure diagram
Source: SIPO (2012)
Figure 2. Detailed cost assignment view of ABC.
there has been no study in the application of the ABC to a
SPEF . The primary objective of this research is to
investigate the feasibility of applying ABC to a SPEF. A
semiconductor services factory has been selected
because its demand has been rapidly increasing during
the past decade. Moreover, there has been widespread
concern of high competition and rising costs, and its
unique characteristics (for example, shape, size,
component, color, etc.) make for a special challenge. As
mentioned earlier, there has been no formal methodology
5. Chien-Lung and Chun-Hao, 449
Figure 3. Analysis of the SPEF cost.
Table 1. Costs of Selected Products at the SPEF Using the Traditional Costing Method (December, 2012)
Product
Photo mask
cases
Reticle
SMIF pods
Mask
clearners
Wafer
cassetles
Wafer shopping
boxes
Amount(number of units) 7,526 6,272 6,859 7,243 7,460
Sales($) 368,407 291,270 286,561 285,812 278,719
Direct material($/unit) 33.63 32.13 29.14 28.65 27.84
Direct labor($/unit) 6.3 5.67 4.97 4.12 3.76
Total direct($/unit) 39.93 37.8 34.11 32.77 31.6
Indirect material($/unit) 3.12 2.98 2.56 2.15 1.87
Indirect labor($/unit) 2.78 2.65 2.13 1.98 1.76
General overhead($/unit) 3.12 3.01 2.98 2.56 2.13
Total indirect($/unit) 9.02 8.64 7.67 6.69 5.76
Unit cost($/unit) 48.95 46.44 41.78 39.46 37.36
for estimating the product costs in a SPEF. Consequently,
the actual product cost, which is the most essential
information for pricing strategy, is unknown. For this
reason, the ABC system is needed to improve the product
costing/pricing.
METHODOLOGY
This research is concern with the development of a proper
ABC model for the SPEF. There are four main steps in
accomplishing this research. First, the product, process,
and current cost system of the SPEF must be studied and
analyzed. Second, a suitable ABC model must be
developed and implemented at the factory.Third, a
comparison between the current costing system and the
ABC system has to be made. Finally, the benefits and
obstacles in the application of the ABC system in the
SPEF must be analyzed.
6. 450 Glo. Adv. Res. J. Manag. Bus. Stud.
Table 2. Activity-Based Costing for a semiconductor services company
Costing item Costing driver
Photo mask
cases
Reticle SMIF
pods
Mask
clearners
wafer
cassetles
wafer
shopping
boxes
Direct material
amount of
usages
21.56 18.43 20.32 22.12 22.12
Direct labor labor time(hr) 5.02 4.89 4.56 5.13 3.23
Depreciation machine time 0.78 0.67 0.67 0.78 0.68
Fabricate number of setup 0.23 0.21 0.18 0.23 0.21
Transportation number of ship 0.18 0.13 0.21 0.18 0.29
Storage space 0.05 0.04 0.03 0.05 0.04
Maintenance
machine
time(hr)
0.21 0.18 0.2 0.21 0.18
Accounting
percentage of
sale(%)
0.19 0.15 0.17 0.19 0.21
Marketing
percentage of
sale(%)
0.24 0.22 0.26 0.24 0.23
Research
&patent
percentage of
sale(%)
0.41 0.43 0.44 0.41 0.39
Human
resources
labor time(hr) 0.15 0.13 0.14 0.15 0.16
Procurement
percentage of
sale(%)
0.31 0.28 0.32 0.31 0.3
Environmental
protection
percentage of
sale(%)
0.02 0.018 0.02 0.018 0.017
Miscellaneous labor time(hr) 0.19 0.15 0.18 0.19 0.21
Unit cost 29.54 25.928 27.7 30.208 28.267
The Company Background
At this research, this company (SME) employed about
250 workers and focused on the semiconductor front-end
lithography process equipment, parts sector, R & D
photolithography process components. The Company of
main production were Photo mask case and Mask
package shipping box. The IC chip was placed in the
Photo mask case for the process of transportation and
storage to maintain its cleanliness protected against air
dust pollution and electrostatic damage. In the market
share of mask box products, The company provide the
high-end masks carrier solutions for the TSMC company
in the mask box products and become market leader in
the world. Under the strategic superiority of the company's
innovative service model, The company pays attention to
the request of the complete supply chain of the world's
semiconductor manufacturers, cooperation through
various successful development of high value-added
products and technologies. In 2012 year, This company
won many reward, such as National Quality Award ,
National Industrial Innovation Award, Innovation
Research Award, and Taiwan Excellence Award.
To better understand the company costs in general, an
analysis and classification of the costs was made (Figure
3). There are two major cost components: indirect costs
and direct costs. Indirect costs consist of indirect material
cost (i.e., Mask Package , screws), indirect labor cost, as
well as general overhead cost. Direct costs include direct
material cost and direct labor cost.
Traditional Cost System for the SPEF
With respect to the traditional cost system for SPEF, the
cost elements are broken down into direct and indirect
costs. The direct costs are directly assigned to the product
according to actual consumption rate. On the other hand,
7. Chien-Lung and Chun-Hao, 451
Table 3. A Comparison between Activity-Based Costing and Traditional Costing System for the
semiconductor services company
Product
Traditional cost
system($)
ABC($)
Difference
($) (%)
Photo mask cases 48.95 29.54 19.41 39.65
Reticle SMIF pods 46.44 25.93 20.51 44.17
Mask clearners 41.78 27.70 14.08 33.70
wafer cassetles 39.46 30.21 9.25 23.45
wafer shopping boxes 37.36 28.27 9.09 24.34
Table 4. A Comparison in Profits between the ABC System and the Traditional Costing System for the
semiconductor services company
Product
sale Price
($/unit)
Traditional cost system($) ABC($)
Cost
($/unit)
Profit
($/unit)
Profit
(%)
Cost
($/unit)
Profit
($/unit)
Profit
(%)
Photo mask cases 50.21 48.95 1.26 2.51 29.54 20.67 41.17
Reticle SMIF pods 48.43 46.44 1.99 4.11 25.93 22.50 46.46
Mask clearners 42.37 41.78 0.59 1.39 27.70 14.67 34.62
wafer cassetles 40.67 39.46 1.21 2.98 30.21 10.46 25.72
wafer shopping
boxes
38.97 37.36 1.61 4.13 28.27 10.70 27.46
the indirect costs are allocated to each product using sale
values in cost application (as shown in Equation (1)). The
cost per product is expressed as follows:
Where is cost per unit for product i ($/unit) ; is
the amount of direct cost consumed by product i ($); TI is
total indirect cost per month ($); TS is total sales (all
products) per month ($); is total sales of product i per
month ($); is amount of product i (number of units);
and i is individual product. Based on the traditional cost
system (Table 1), the cost of each product can be
averaged to get the average cost per unit. Thus, the cost
per unit for Photo mask case (using Equation (1)) in this
example is $48.95: [$37.32 + (266,111/1,510,769) ×
(368,407/7,526)]. The major problem in this approach is
that it assumes that all products are alike (the indirect
costs are equally assigned to each product based on sale
values). This is an unreasonable assumption, because
the resources (indirect costs) consumed by the product
may vary significantly from product to product. This may
lead to inefficiency in making decisions due to less
accurate information.
Application of Activity-Based Costing in the SPEF
To improve the traditional costing system, the ABC system
was adapted for this research (Figure 3). The cost per unit
using the ABC system was calculated as follow:
)
1
(
]
*
[ −
−
+
=
i
i
i
i
N
TS
TS
TI
D
UC
i
UC i
D
i
TS
i
N
8. 452 Glo. Adv. Res. J. Manag. Bus. Stud.
where is cost per unit for product i ($/unit); is the
amount of direct labor cost consumed by product i ($) ;
is the amount of direct material cost consumed by product
i ($); are costs associated with activity j assigned to
product i (based on a specific cost driver, $); j is individual
activity, 1, 2, 3, . . . , m; and i is individual product.
Implementation Procedure for Activity-Based Costing
for the SPEF
There are six steps involved in adapting the ABC system
to the SPEF in this research. There are outlined as
follows:
Step 1. Identifying Products for Analysis
The first step is to select the products for this analysis.
The selection may be based on volume (high volume),
financial impact (high cost, low profitability), special
interest (new product), or variance measures (high
variance from cost estimation). For the purpose of
illustration, the top five products accounting for 78.45% of
all sales are considered for this research. They are Photo
mask cases, Reticle SMIF pods,Mask clearners,Wafer
cassetles, and Wafer shopping boxes.
Step 2. Reviewing the Company’s Financial
Information
Most of the needed financial information can be obtained
from the company’s income statement, balance sheet,
production reports and other materials. Yet, some
information could be obtained by direct observations such
as production operations, machine setup activities, and
transportation.
Step 3. Identifying and Classifying of Activities
(Activities Analysis)
All activities associated with the products are identified
and classified. The activities are further categorized into
direct activities and indirect activities. Direct activities are
those that can be directly assigned and linked to the
products. Indirect activities are those that are not directly
associated with the products (i.e., administration,
depreciation, etc.). To optimize decision making efficiency,
the direct activities are further grouped into two major
categories: direct labor (number of hours of operations)
and direct materials (amount of plastics usages). This is
because the labor and materials, altogether, account for
more than 87% of the total cost.
Step 4. Determining Operating Cost for Each Activity
Once the activities are clearly identified, the operating
costs are calculated for each activity. These costs should
represent resource consumption by each activity.
Step 5. Selecting the Cost Drivers
Cost drivers are used to trace the cost of each activity to a
product based on its consumption rate. As the indirect
activities for operating the factory are identified, they are
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9. linked to each product based on the activities undertaken
to produce each of the specific products. For illustration,
determining the cost of machine maintenance using the
value of sales is an inappropriate method. A more
accurate calculation can be obtained by using the actual
number of machine hours in operation (operating time).
This is because the more one uses a machine, the more
maintenance, rental, and replacement one would require.
In addition, direct labor hours are appropriate for applying
costs of administration, professional fees, recruitment,
and employee training, because these activities are
associated with direct labor.
Step 6. Calculating Product Costs
Finally, all activities are traced to the products using
different cost drivers in order to obtain the final costs.
RESULTS
Table 2 illustrates the cost per unit for the previously
selected products using the ABC system. Only the major
cost drivers (main activities) are presented in this table.
With the use of the ABC method, the unit cost for the
Photo mask cases, Reticle SMIF pods , Mask clearners ,
wafer cassetles , and wafer shopping boxes are $29.54,
$25.928, $27.7, $30.208, and $28.267, respectively. To
discuss this in more detail, the cost per unit for Photo
mask cases consists of the following major costing
categories: direct material, direct labor, depreciation,
Fabricate , transportation, storage, maintenance,
accounting,marketing, research & patent ,human
resources, procurement, environmental protection, and
Chien-Lung and Chun-Hao, 453
miscellaneous for $21.56, $5.02, $0.78, $0.23, $0.18,
$0.05, $0.21, $0.19, $0.24, $0.41, $0.15,$0.31,$0.02 and
$0.19, respectively. As illustrated in the semiconductor
services company example, various cost drivers can be
chosen by applying indirect activities to the products
under ABC as long as a cause–effect relationship is
evident. Traditional costing, on the other hand, uses
values of sales-related allocation based on amount of
sales per month in its cost application.
A comparison between the ABC and the traditional
costing system for the semiconductor services company
is presented in Table 3. As expected, the costs computed
by the two approaches are different. The costs under the
ABC system are lower than the traditional cost system.
The difference is most significant for the Reticle SMIF
pods , showing a $20.51 decrease (−44.17%).
With respect to the product pricing, the results indicate
that the prices of all products are higher than their costs
under the traditional costing system (Table 4). The profit
margin is significant for wafer shopping boxes (4.13%)
and Reticle SMIF pods (4.11%). However, the difference
is only 1.39% (price of $42.37, cost of $41.78) for the
Mask clearners and 2.98% for the wafer cassetles (price
of $40.67, cost of $39.46). In other words, the factory
obtains a profit from all products under the current costing
system. With regards to the ABC system, the prices of five
products are higher than their costs. Following the same
trend as the traditional costing system, the profit margin is
considerable for the Reticle SMIF pods (46.46%) and the
Photo mask cases (41.17%).
Finally, the result of ABC analysis indicates that the
material cost has the greatest influence on the cost
structure. For example, the costs of Mask Package per
product for Photo mask cases , Reticle SMIF pods , Mask
10. 454 Glo. Adv. Res. J. Manag. Bus. Stud.
clearners, wafer cassetles and wafer shopping boxes are
72.99 ,71.08, 73.36,73.23, and 78.25 of the total cost,
respectively. In other words, the average cost of Mask
Package material is about 73.78% of the total cost. In
contrast, the indirect cost has the least impact on the
overall cost structure, accounting for 17.55% of the total
cost. Clearly, the first priority should be concerned with
cost reduction by minimizing the cost of Mask Package.
DISCUSSIONS AND MANAGERIAL IMPLICATIONS
The semiconductor services company has the capacity
and capability of producing many kinds of products, but it
is unsure what products and quantities it should produce
in order to become more profitable. Currently there are
many products that are overpriced (Photo mask cases ,
Reticle SMIF pods , Mask clearners, wafer cassetles and
wafer shopping boxes ). Based on this research, the
factory seems to obtain a profit from Photo mask cases ,
Reticle SMIF pods , Mask clearners, wafer cassetles and
wafer shopping boxes. The most significantly overpriced
item is the Reticle SMIF pods , at 46.46% above the
current selling price. Another highly profitable item is the
Photo mask cases, at 41.17% above the selling price. For
a particular example, the cost of the Reticle SMIF pods
using the traditional costing system is $46.44, whereas
the cost using the ABC is $25.93.
With the actual price being $48.43, the factory will gain
more profit using the ABC system, and the customers will
be at a disadvantage. However, competitors can take
advantage of the factory’s poor decisions based on
inaccurate cost information (higher than actual) by
reducing the price of the Reticle SMIF pods to make it
more appealing to customers. This means that the factory
will likely not be as competitive and will lose their business.
A significant lesson learned from this research is that the
allocation of sales can distort product costs by shifting the
activity costs involved with relatively low sale values to
those with high sale values. The problem worsens when
the lower sale value products are small in number and
production runs must be set up frequently, whereas the
higher sale value items involve long running times,
infrequent setups, and are considered standard products
that require no special handling or attention. Producing
these low-volume products means that the time that could
be used for processing a value-added activity must be
used to set up a non-value-added activity, consequently
causing the manufacturing overhead to rise.
In addition, by applying ABC, the factory can identify
non-value-added activities that consume resources
without adding value to the products. This assists
management in effectively reducing costs by focusing on
the non value- added activities. The identification of the
non-value-added activities occurs through this process
with a clarity that allows management to eliminate them
and, at the same time, delivers the products to the
customers with greater efficiency. For illustration,
methods studies and ergonomic principles should be
applied to reduce or eliminate the non-value-added
activities, such as setups, idle time, and preparation. For a
specific example, the number of machine setups may be
reduced by better production planning. The operator’s idle
time can be reduced by proper line balancing. At the
same time, the useless scrap can be reduced by better
production design and appropriate sawing techniques.
There are numerous challenges in implementing the
ABC system in a manufacturing environment. First,
collecting the data needed to establish the ABC system is
time consuming and expensive. For example, in order to
11. determine the labor cost for the Mask clearners , it takes
around 250 h to determine the processing time in each
production task. The ABC system is much more complex
in detail than the traditional cost system, because costs
are allocated to different activity pools that are further
broken down into several separate activities. This requires
detailed analysis of financial accounting records, as well
as diligent observations to identify and gather costs and
other information regarding specific activities. Also, the
statistical analysis (i.e., sampling techniques, concept of
estimation, and numerical descriptive measures) required
to allocate costs is much more complex for the ABC
system. For instance, the sampling technique is employed
to identify the method of data collection for determining
standard time in production processes. The major
advantage of the ABC method lies in a more accurate
cost computation, especially in situations in which product
diversity is important and in which the indirect costs
represent an important proportion of the total cost.
Although the indirect cost, which has the most impact on
the ABC approach, accounts for only 17.65% in the
semiconductor services company, its trend will be steadily
increasing. This is because the semiconductor services
companies have been constantly changing from labor
orientation to high-technology manufacturing
environments. As discussed by Ruhl and Bailey (1994), in
a business environment characterized by high technology,
overhead cost is a large percentage of the total
manufacturing cost.
CONCLUSION
As discussed in this article, the ABC system provides
more accurate product costing information than a
traditional costing system (Park & Simpson, 2008;
Chien-Lung and Chun-Hao, 455
REZAIE et al, 2008). The ABC model has decided to
acquire a new type of equipment/technology to improve a
process and deliver a superior performance to its
customers, and suppose that this change requires in turn
the acquisition of one or more individual competencies
(Cannavacciuolo et al,2012). It also provides insight into
the product cost structure. Furthermore, it allows
managements to identify costly and unprofitable products.
Once the costly products are identified, other industrial
engineering techniques can be applied to either reduce or
eliminate the non-value-added activities for such products.
This integration might offer significant opportunity for cost
reduction. However, the ABC system is a time-consuming,
labor-intensive process, and its success depends on the
total participation of every unit in the organization.
Managers who recognize the need for the ABC may be
apprehensive of the changes brought by a new system
and may resist that change. In such cases, organizations
may miss out on significant improvement
opportunities.Therefore, it is important to consider the
phenomenon of resistance to change by individuals and
organizations in the context of the ABC. All in all, it should
be acknowledged that the ABC system is a useful tool for
better management of the business. It would be an
important aid in making management decisions,
particularly for improving pricing practices by making
costing more accurate. Thus, it can play a significant role
in a factory’s success.
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