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Cost Advantage ,[object Object],[object Object],[object Object],[object Object],OUTLINE
The  Experience Curve The “Law of Experience” The unit cost value added to a standard product declines by a constant % (typically 20-30%) each time cumulative output doubles. Cost per unit of output (in real $) Cumulative Output 19 92 19 94 19 96 19 98 2000 2002 2004
Examples of Experience Curves 100K 200K   500K  1,000K   5   10   50 Accumulated unit production   Accumulated unit s (millions)   (millions) 1960 Yen 15K  20K  30K Price Index 50  100  200  300 70% slope 75% Japanese clocks & watches, 1962-72 UK refrigerators, 1957-71
The Importance of Market Share ,[object Object],[object Object],[object Object],BUT : -  Association  does not imply  causation - Costs of acquiring market share offset the returns to market   share ROS (%) -2  0   5 10 0-10  10-20  20-30  30-40  over 40 Market Share (%)
Drivers of Cost Advantage PRODUCTION TECHNIQUES PRODUCT DESIGN INPUT COSTS CAPACITY UTILIZATION RESIDUAL EFFICIENCY ECONOMIES OF LEARNING ECONOMIES OF SCALE ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Economies of Scale: The Long-Run  Cost Curve for a Plant Units of output per period Minimum Efficient Plant Size: the point where most scale economies are exhausted Cost per unit of output Sources of scale economies: - technical input/output relationships - indivisibilities - specialization
The Costs Developing New Car Models   (including plant tooling) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Scale Economies in Advertising: U.S. Soft Drinks 10  20  50  100  200  500  1,000  Annual sales volume (millions of cases) Advertising Expenditure ($ per case) 0.02  0.05  0.10  0.15  0.20 Coke Pepsi Seven Up Dr. Pepper Sprite Diet Pepsi Tab Fresca Diet Rite Diet 7-Up Schweppes SF Dr. Pepper Despite the massive advertising b udgets of  brand leaders Co ke  and Pepsi, their main brands incur lower advertising costs per unit of sales than their smaller rivals.
Cost Advantage in Short-Haul  Passenger Air Transport Costs per Available Seat-Mile  Southwest Airlines   United Airlines   (cents)   (cents) Wages and benefits 2.4 3.5 Fuel and oil 1.1 1.1 Aircraft ownership 0.7 0.8 Aircraft maintenance 0.6 0.3 Commissions on ticket sales 0.5 1.0 Advertising 0.2 0.2 Food and beverage 0.0 0.5 Other 1.7 3.1 Total 7.2 10.5
Applying the Value Chain to Cost Analysis:  The Case of Automobile  Manufacture STAGE 1. IDENTIFY THE PRINCIPLE ACTIVITIES STAGE 2. ALLOCATE TOTAL COSTS PURCH- ASING PARTS INVEN- TORIES R&D DESIGN ENGNRNG COMPONENT MFR ASSEMBLY TESTING, QUALITY CONTROL GOODS INVEN- TORIES SALES & MKITG DISTRI- BUTION DEALER & CUSTOMER SUPPORT
Applying the Value Chain to Cost Analysis: The Case of Automobile  Manufacture (continued) PURCH- ASING PARTS INVEN- TORIES R&D DESIGN ENGNRNG COMPONENT MFR ASSEMBLY TESTING, QUALITY CONTROL GOODS INVEN- TORIES SALES & MKITG DISTRI- BUTION DEALER & CUSTOMER SUPPORT   --Plant scale for each   -- Level of quality targets   -- No. of dealers   component   -- Frequency of defects   -- Sales / dealer   -- Process technology     -- Level of dealer   -- Plant location   support   -- Run length   -- Frequency of defects   -- Capacity utilization   under warranty Prices paid    --Size of commitment   -- Plant scale   --Cyclicality  & depend on:   --Productivity of  -- Flexibility of production    predictability   of sales -- Order size    R&D/design  - -  No. of models per   plant --Customers’ -- Purchases per    --No. & frequency of new  -- Degree of automation    willingness to wait  supplier    models   -- Sales / model   -- Bargaining power -- Wage levels -- Supplier location  -- Capacity utilization STAGE 3. IDENTIFY  COST DRIVERS
[object Object],[object Object],Applying the Value Chain to Cost Analysis: The Case of Automobile  Manufacture (continued) Consolidation of orders to increase discounts, increases inventories Designing different models around common components and platforms reduces manufacturing costs Higher quality parts and materials reduces costs of defects at later stages Higher quality in manufacturing reduces warranty costs STAGE 5. RECCOMENDATIONS FOR COST REDUCTION STAGE 4. IDENTIFY LINKAGES
Dynamic vs. Static Approaches to Manufacturing PRODUCTION SYSTEM MANAGEMENT OF TECHNOLOGY DYNAMIC (Artisan Mode) STATIC (Scientific  Management Mode) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Recent Approaches to Cost Reduction ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],CORPORATE RESTRUCTURING BUSINESS PROCESS REENGINEERING

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Ch08

  • 1.
  • 2. The Experience Curve The “Law of Experience” The unit cost value added to a standard product declines by a constant % (typically 20-30%) each time cumulative output doubles. Cost per unit of output (in real $) Cumulative Output 19 92 19 94 19 96 19 98 2000 2002 2004
  • 3. Examples of Experience Curves 100K 200K 500K 1,000K 5 10 50 Accumulated unit production Accumulated unit s (millions) (millions) 1960 Yen 15K 20K 30K Price Index 50 100 200 300 70% slope 75% Japanese clocks & watches, 1962-72 UK refrigerators, 1957-71
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  • 6. Economies of Scale: The Long-Run Cost Curve for a Plant Units of output per period Minimum Efficient Plant Size: the point where most scale economies are exhausted Cost per unit of output Sources of scale economies: - technical input/output relationships - indivisibilities - specialization
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  • 8. Scale Economies in Advertising: U.S. Soft Drinks 10 20 50 100 200 500 1,000 Annual sales volume (millions of cases) Advertising Expenditure ($ per case) 0.02 0.05 0.10 0.15 0.20 Coke Pepsi Seven Up Dr. Pepper Sprite Diet Pepsi Tab Fresca Diet Rite Diet 7-Up Schweppes SF Dr. Pepper Despite the massive advertising b udgets of brand leaders Co ke and Pepsi, their main brands incur lower advertising costs per unit of sales than their smaller rivals.
  • 9. Cost Advantage in Short-Haul Passenger Air Transport Costs per Available Seat-Mile Southwest Airlines United Airlines (cents) (cents) Wages and benefits 2.4 3.5 Fuel and oil 1.1 1.1 Aircraft ownership 0.7 0.8 Aircraft maintenance 0.6 0.3 Commissions on ticket sales 0.5 1.0 Advertising 0.2 0.2 Food and beverage 0.0 0.5 Other 1.7 3.1 Total 7.2 10.5
  • 10. Applying the Value Chain to Cost Analysis: The Case of Automobile Manufacture STAGE 1. IDENTIFY THE PRINCIPLE ACTIVITIES STAGE 2. ALLOCATE TOTAL COSTS PURCH- ASING PARTS INVEN- TORIES R&D DESIGN ENGNRNG COMPONENT MFR ASSEMBLY TESTING, QUALITY CONTROL GOODS INVEN- TORIES SALES & MKITG DISTRI- BUTION DEALER & CUSTOMER SUPPORT
  • 11. Applying the Value Chain to Cost Analysis: The Case of Automobile Manufacture (continued) PURCH- ASING PARTS INVEN- TORIES R&D DESIGN ENGNRNG COMPONENT MFR ASSEMBLY TESTING, QUALITY CONTROL GOODS INVEN- TORIES SALES & MKITG DISTRI- BUTION DEALER & CUSTOMER SUPPORT --Plant scale for each -- Level of quality targets -- No. of dealers component -- Frequency of defects -- Sales / dealer -- Process technology -- Level of dealer -- Plant location support -- Run length -- Frequency of defects -- Capacity utilization under warranty Prices paid --Size of commitment -- Plant scale --Cyclicality & depend on: --Productivity of -- Flexibility of production predictability of sales -- Order size R&D/design - - No. of models per plant --Customers’ -- Purchases per --No. & frequency of new -- Degree of automation willingness to wait supplier models -- Sales / model -- Bargaining power -- Wage levels -- Supplier location -- Capacity utilization STAGE 3. IDENTIFY COST DRIVERS
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Editor's Notes

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