Capacity Increases…So Costs Decrease??

Last week Tara and I presented an educational program to a group of business professionals on the subject of cost accounting and current trends in cost accounting. As always this was an interesting conversation with a number of participants bringing issues to the group relative to problems they see in their everyday application of cost accounting standards while working in a variety of business environments. One of the more interesting questions had to do with an attendee who came from a service oriented environment where fixed costs accounted for a large portion of the total costs. This attendee’s question was in times of expanding services where the capacity of the company was being developed and expanded to take on new customers and perhaps new services, it seemed the cost of the those services decreased.

The question really relates to the allocation of fixed cost among an ever-increasing population of work to be done. His point was as capacity increases it reduces the fixed charge to existing customers thereby making them cheaper. He recognized that just because capacity changes the cost to provide other services is not any cheaper, and it can actually be misleading for management to believe that a service that cost one dollar before increased capacity now cost $.80 because of the fixed charge coverage ratio.

This is a reoccurring problem in cost accounting particularly in an environment that has a large component of total costs being fixed costs.

Part of the promise of ABC (activity-based costing) is that those fixed charges can be more precisely identified to the services that are using them thereby changing the fixed cost to something more like a variable cost and more precisely identified to the services that are using the cost. If this can be done then by all means that methodology should be chosen to more precisely identify those cost to the services that utilize them. However, if such allocations are very arbitrary and all you’re really seeking to do is another method of apportioning overhead, then the real question has to do with what impact that will have on the earlier-based services.  Especially when new services are added which will thereby increase capacity. The attendee at this seminar’s point was that the cost does not get cheaper because of increased capacity.  My response was well that depends!  It depends on if you are attempting to use fully loaded cost as the method of analyzing the cost of your services then -yes it is probably true.  Really for all services as capacity is increased, the per unit charge for those services is decreased. This is true because you have a much larger base now to spread those fixed charges over and in respect of how you do the accounting that does result in a lower price per unit for existing services and new services. However I believe what this attendee was referring to was not the total cost of providing services but rather the effects on the direct cost of providing those services and changes in fixed overhead. His point, I believe, was that the actual cost, the direct cost, of providing those services is not affected at all by the total increase in volume but rather those allocated costs tend to muddy the waters for purposes of management oversight and create a misconception that the services themselves are using less resources.

I would say this is probably a good example of choosing which cost you use to analyze the operations. In this case if you’re attempting to determine what the cost are of certain services you have to look exclusively then at just the direct cost of those services not including an apportioned or allocated overhead as part of that presumption.

We over and over again run into accountants who attempt to compute one cost for every purpose. If you’re trying to use one fully loaded cost to make all comparisons and provide all management information you’re going to find that misaligning results are going to be an absolute byproduct of that process.

I would suggest that different costs for different purposes get the most meaningful results and best suit management’s purposes when attempting to determine the actual total cost of the project or the profitability for some services. If virtually all of your costs are fixed cost then that leads to a whole other problem for purposes of analyzing the profitability or the total cost of services and there are several tools available to do that; however, that is a unique circumstance and has to be dealt with separately particularly in today’s business environment.

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Honesty Can Go Down Like a Jagged Pill

I recently read a blog post by Gary Cokins titled “Analytics Takes the Thumb Off the Scale.” In this post Gary talks about an article written by Eric Garland titled, “How So-Called Strategic Intelligence Actually Makes us Dumber.” This particular article discusses how instead of always divulging the sometimes painful truth, we voice what people want to hear.  He talks about how we want to make people feel better and provide emotional comfort instead of providing people with real world information for real world decisions.  I’m curious as to what your thoughts are about that concept?

Gary Cokins deemed there to be truth to the article, what do you think?  I also believe there is some truth to it, but I am not perhaps as convinced that the information bearer is concerned with making sure their bosses feel good.  I do not think the controller cares that much about the CEO, CFO, etc. in that they want them to be happy, I think they want them to be happy because selfishly that means their life is better.  If the boss is happy, I am happy-right?  So the controller often tells the CEO “feel-good” information to make life easier; not because he is concerned with the boss’s feelings.

I believe people determine what direction they want their numbers to go and they find information that will support those findings, and avoid those that will not.  It is not that the opposite isn’t glaring them in the face; it is that they choose to look the other way.  I think that “gut feelings”  are still there and people still get that “pit in their stomach feeling,” but  they have just become really good at ignoring it, because listening to it means things will be a lot more difficult!

I also often wonder if individuals would rather keep things positive because then no one will dig too much.  I believe many controllers are concerned that they will be exposed and their lack of overall knowledge will be brought to light. When everything is supposedly going well people tend to accept it.  When things are going poorly everyone wants to know why and they start to try and uncover the inaccuracies.

No matter how grim reality is, that is what needs to be portrayed because, well, its reality!  Good decisions can only be made with good information.  Living in a dream world and giving faulty information can only last for so long.  Eventually things will come crashing down.  It is better to be honest and deal with problems as they come, then to be fired for creating even larger problems.  We need to start providing our CEO’s with the most accurate information no matter how difficult of a pill that is to swallow.

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“Financial Statements Don’t Mean Anything, No One Understands Them!”

This is a direct quote from Larry White, former IMA Chair, Director of the Resource Consumption Accounting Institute, and Chairman of the IMA’s Managerial Costing Conceptual Framework Task Force.  He presented at the Spring Management Accounting Conference in Detroit a few weeks ago, and I noted a few comments that he made that I could not help but agree with:

Traditional financial statements as we see them are governed by many, many rules on what you are allowed to record, how you record it, when you can record it, and even the amounts you have to record.  Being the “non audit type” that I am, many of the rules seem illogical to me, so I second his motion.  I look at the numbers from a completely different vantage point, and the financial statements always seem to mask the reality of what is really happening in the business.  They are a good starting point, but never a place to end if you are accurately trying to identify the core practices and anomalies that are occurring on a daily basis.

In comes management accounting, which is receiving a great deal of exposure as of late.  Larry’s point that he was trying to make was that financial statements as we know them have a very well defined framework that each company must follow.  However, in dealing with management accounting, there truly are not any rules to follow.  Another quote: “How many years have we been doing this (managerial accounting) and no one has written it down?”  Well said and very true.  A framework for “writing it down” has been developed, with Larry in the lead.

I struggle with this, because to me, management accounting is instinct, more than the “norm” of GAAP based statements.  I think it would be very difficult to set concrete rules as to how management accounting should be done.  Guidelines and definitions are most appropriate, which I believe is the approach being taken.  Every company, industry and process is so uniquely different that it would be impossible to dictate management accounting and/or costing guidelines for all simultaneously.  That is an impossible task.  My opinion is that we have tried; through the evolution of the many, many costing techniques that we keep naming to “write it down.”  What works for your Company may not be appropriate for another, and might result in wildly erroneous figures, simply because of the different procedures your Company employs to generate product.

If you are the CEO of your company, don’t rely on the financial statements alone! Larry is right, they don’t mean anything.  If you are the Controller or CFO for your Company, make sure that in addition to your GAAP basis financial statements, you are providing management reporting that MEANS SOMETHING.

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Coloring Easter Eggs and Cost Accounting

I hope everyone had a Happy Easter!  I traveled home to visit my family which is about 3 hours away from where I live.  It was nice to get away and visit, but it is always hectic. My husband’s family is also from the same area, so there are quite a few people to see in such a short time.  I hope everyone was able to enjoy some quality time with family and friends without the chaotic schedule I experienced. So how can I relate Easter and costing?  I’m wondering the same thing, but keep reading and we will find out together!

As I arrived at my parent’s home on Saturday afternoon after working several hours Saturday morning, I really just wanted to sit down and rest a few moments before heading over to my in-laws home.  But my mom had other plans; she had everything set up to color eggs.  She insisted we have some colored eggs for the Easter table, so of course not wanting to disappoint her, I jumped right in.  She began telling me about all the colors she had made based on the formulas on the food coloring box.  My excited accounting mind started to think about how precise she had to be with creating the colors for the eggs.  Add too much red to green and yellow, you get brown. The same will occur if you add to much red to blue while trying to make purple. So really there is a precise science to making the egg dye!  Thankfully all I had to do was drop the egg in the color and let it sit there! As the egg soaked, I thought about cost accounting and something my colleague, Bill Horst, often says: “it is better to be approximately right than precisely wrong.”  Often times in cost accounting we think we have to be so accurate, don’t get me wrong, accuracy is good, but if you are completely wrong then it is utterly worthless!

Make sure you understand what you are doing and what your goals you are trying to meet. Do not aim at something to try and be too complex.  Just because something is complex, does not mean that it is accurate, and just because something is simple, does not mean it is not sophisticated.  It is most important that you understand what you are doing and why it is being done.  It doesn’t have to be as accurate as the colored water for coloring eggs, but it does need to be correct and understandable.  Take a step back and look at your current process.  Can you follow it all the way through and understand each step, or is it just precisely wrong?

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Manual vs. Machine Labor: How Do They Fit Into Overhead Allocation?

Two recent client meetings brought to the surface similar costing issues.  Both clients were in different industries. However, the facts and circumstances surrounding each of their problems were surprisingly similar! At the conclusion of the second meeting, it was clear to me that this was likely a very common problem. As with most companies utilizing standard costs, both companies’ roots were from a labor controlled environment. Even though there were multiple machine processes happening, each of those processes was being loaded, unloaded and controlled by a single operator. Appropriately at the time, both companies chose direct labor as the method of accumulating cost and allocating overhead to production parts.

As with any manufacturer who wishes to remain competitive, technology now dominates the production process.  The rule is no longer people controlling machines, but it is machines running automatically with very little human intervention. In fact in both cases, other than occasionally loading a machine, the human touch is very minimal. The management team at both companies realized that they were getting radically differing results depending on what machine they were working on, but they did not have a full understanding of what was causing such results or the process it would take to resolve the problem.

At both companies the older non-automated equipment was still in general use throughout the plant and both had components of their operations which were labor controlled.  When I questioned them about labor being the most relevant allocation base for all of their parts produced, the thoughtful reaction to me were irrefutable.

Problems like this are best resolved by analyzing all of the activities that occur as part of production and choosing the base or bases that are the most stable and that best represent how overhead is incurred in the plant.  The best solution or combination of solutions can be very different to what might seem like similar circumstances.

These circumstances are not much different than what we have discovered over and over again as part of our educational seminars related to cost accounting. These cost forums always attract cost managers who are dealing with difficult problems, but remarkably they are quite similar to other participants costing issues. Having done many of these forums, we have categorized these types of problems and their solutions in the five main categories:

  1. Financial Budgeting
  2. Cost Components
  3. Cost Allocation
  4. Systems Challenges
  5. Reporting Issues

We have had great success in helping businesses resolve issues in each of these categories regardless of the size or nature of the business.

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Do You Know Where You are Going?

At a recent CPE course I attended, Doug Hicks referenced a classic clip attributable to the infamous Monty Python: http://www.youtube.com/watch?v=VI4q4ShXNYw

When the gun sounds, everyone runs in a different direction!  I thought this was such a good example of so many of the businesses I consult with, especially when it comes to costing.  As so many costing “experts” have pointed out, there are no clear guidelines for management accounting and how to cost your product.   If you are at the starting point, there are endless methods that can be utilized, so how do you know where to begin?

I am not an “expert,” although I have extensive costing experience with a multitude of manufacturing clients.  During our costing forum we walk through some of the key components that must be built in to your costing system for it to be effective.  However, that does not in any way cover all of the concepts that need to be considered while undertaking this process.  Here are just a few that I consider to be essential for success:

  • Know your process – It is impossible to identify costs, transactions, and any anomalies that should be attributed to the cost of a product if you don’t know, or understand the process of producing that product from beginning to end.  This includes commitment of the raw material to the process until the item has reached its destination, and even the customer service at the front and back end of the order process.
  • Be part of the team – I can almost say every company I visit one of the first issues that comes to light is that every department, and sometimes every team member, has their own spreadsheets with their own method of costing the product.  EVEN IF there is a sophisticated general ledger package,  each department brings a unique knowledge of the product to the table.  There needs to be roundtable discussions with all departments to make this knowledge common to the group so everyone can agree about what costs are actually incurred and relevant when manufacturing the product.

  • Don’t think of product costs strictly in terms of materials, labor, and a “spread” overhead. In today’s extremely competitive manufacturing world,  production of a single part is significantly more complicated than in the past, and as a result each product can have significantly different costs.  Some that are not commonly considered include:  transportation and packaging, costs to receive/ process or make ready, logistics expenses (loading, unloading, handling),  quality costs, regulatory or environmental costs, and finally, customer specific handling costs such as excess service time or particular sales and/or payment terms.
  • Transparency is key – While you want to identify some of the above costs if they are significant to a particular customer or part, don’t go overboard in trying to allocate every single cost down to the last penny in the general ledger.  That will do nothing but waste your time and lead to frustration.  For example, if 18% of your packaging expense can be directly attributed to a single product, that should be segregated in your costing model. Precision and accuracy are important, but you must be logical in determining the benefit of too much precision.

  • Don’t blindly accept anything – Translated, get to the bottom of it!  When working with the results of your cost system (variances) you need to investigate.  Make sure you understand what is acceptable for your business model and what is not.  How many times can the same variance occur?  Is there a trend in the variances that may be immaterial on a period basis but if you charted it you would see the relevance?  Find the answers and fix the problems.

These comments are not nearly all encompassing, but strictly my opinions based on my experience.  Because the costing continuum is so unique to each company, it would be impossible to detail the steps you should follow.  The IMA is working on a structural framework (see the October 2011 issue of Strategic Finance), concepts to follow, but it still cannot give you detailed marching orders to execute your plan.  It requires time, commitment, and the ability to process numbers in a manner different than your typical accountant.

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Timing is Everything

I have been working with a client who one month has high profits, and then the next has losses.  He is very perplexed as to why this is occurring and of course, to any financial institution, he appears volatile and they steer clear.  There is an obvious answer to his dilemms and its timing!  The cost is being recorded in one month and the sale in another.  This leaves income very low or at a loss when all the cost is recorded and then income very high when the income is recorded. It makes perfect sense, but occurs all too frequently.  The issue is that the accountant records the cost on the books when the finished good is sent, which is correct. But then records the sale in the next month when the invoicing is done.  The opposite is also true with receipt of product.

Ideally a filing system should contain 3 files for purchased products: one for outstanding Purchase Orders (PO’s), another for receiver reports and a third for invoices received from the customer.  Every time a receiver report is collected it should be matched with the correct PO. Then, when the invoice is obtained it should be matched to the appropriate PO and receiver.  The issue here is that a receiver may be accepted on March 29th, but the invoice from the customer may not be received until April 10th.  The invoice, when in the accountant’s possession, should be entered in March since the product was received in March, not in April when the invoice was delivered.  In order to prevent having to remember what belongs in what period, the file for the month should have the correct documents waiting to be matched up to the invoice that came in on April 10th.

The same school of thought goes for invoices prepared.  The filing system should have two folders for that process: one for shipping reports and a second for invoices.  If the product is shipped in March, it should be invoiced in March. However, that does not mean you have to physically do the invoice in March, it just means it needs to be dated as of March.  The process would then be to match up the invoices and the shipping reports from when the product was sent.

Another important piece of the puzzle is accurately costing and recording your inventory in each period.  This is something we have discussed in previous posts and will continue to in future posts.  If your costing is not transparent then there is no proof of accuracy, which means there is no guarantee that your financial records are accurate.  Have good records so you can make timely and beneficial decisions is essential in the success of any business.  Don’t keep leaving things up to chance!

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Expansion: Are You Set For Success or Failure?

Recently I attended a seminar that included a variety of speakers specifically focusing on management accounting topics. Two of the speakers chose to center their discussion on why businesses fail. As part of this, they gave an overview of two likely ways in which businesses might expand:

  1.  The first is through capacity, which was defined as doing more of the same thing that you have been doing but attempting to expand your horizons in your marketplace by acquiring different customers.
  2.  The second was related to offering different services, or expanding capabilities.

If a business is going to expand their capabilities they are entering a new arena of product line or service which may have radically different features compared to their exsiting line of business.  These speakers focused on the four deadly sins of a business attempting to expand its capabilities and how any of the four might spur the end of the entire business. These sins are all related to business management not fully understanding one of these four components:

  1. systems implementation
  2. product economics
  3. micro business economics
  4. operating strategy limitation

As they went through their description of how each of those four deadly sins could lead to catastrophic results, I was struck by the fact that at least three of the four had implications related to having your job cost and your management reporting process timely and accurate. One of the items they mentioned under the systems implementation was if you’re expanding into a new market via a new product line is that in order for your systems to be operating efficiently, the reports must be accurate, timely and transparent.  Managers can only react to a changing environment if they know and understand what factors are affecting the results in the new environment. Reporting systems that are slow, inaccurate or not readily transparent to those who use them can and will contribute to an inefficient system that in itself can create a disaster.

The one item associated with product economics was directly related to job costing. In this category the speakers were focused on the various levels of profitability created by the new system, service, or product line. They were very focused on management’s ability to extract margin calculations at a number of steps throughout the process. The first margin that they pointed out was the gross margin computed simply on material cost in relationship to the sale price. Particularly in a product line or service that had a heavy material cost, this margin can be extremely critical to understanding the rest of the economic cycle.

The second calculation they were interested in was the contribution margin. This is a summary of all the variable costs associated with the new product or service, and how that might look in compared to the other products or services the company has been offering in the past.

The third item was the overall gross margin. Gross margin included not only the direct costs, but all of the manufacturing allocated indirect costs and approximated a full absorption cost for the new product or service. That margin must be known to adequately understand the calculations and the ultimate impact the product was having on the bottom line profitability of the company.

The last item that they were interested in was the operating margin. This is the fully loaded cost including general and administrative expenses and how these new products or services fare in relationship to other products and services.

No matter what cycle or stage of growth your business is in, knowing accurately computed and transparent job costs is absolutely crucial. Each of these different margin calculations are necessary to evaluate current results and to anticipate future results of expansion, whether by growth from existing product lines and customers, or expanding your services into new products and services.

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You CAN Teach an Old Dog New Tricks: Eliminating the Bottleneck Mindset

I by no means consider myself a procrastinator! In fact, I am as opposite as they come. However, these days there are just not enough hours in the day to get everything done.  I know my public accounting counter-parts empathize and share these mutual feelings, as I am sure many of you reading do as well. Last night, I was prioritizing what I had to do and recognized that I still had not made it down my list to writing this blog post.  I decided it would be my “first thing in the morning project,” which is what I am doing now, and I was hoping inspiration would come my way.  I subscribe to some other blogs, one of which is authored by my former accounting professor Dr. David Albrecht titled,  The Summa.   I received an email a couple days ago from this blog and the title of his recent post was “Do Aging Accountants Create a Bottleneck?” From the title I thought, wow there is some inspiration.  I could talk literally about bottlenecks in production and the constraints caused by them and issues and possible solutions.  Things like not meeting customer demand, having large idle times where you pay workers to stand around, and ultimately the potential for going out of business.  Solutions like reworking the product, reconfiguring the design of your factory, cross training your workforce so they can multi-task during the bottleneck interval, etc.  I think that is all well and good, but apparently I just wrote about that in two sentences!

Ok so, I just read Dr. Albrecht’s blog in real time and although it was good, it talked more about aging professors and not about real-world accountants.  I have a lot of respect for professors, in fact I have some great friends who are educators including my husband who is a high school teacher. I myself have also taught as an adjunct professor. However, I am not sure all accounting professors live in the real accounting world.  Has anyone ever had a situation where it was exactly as your text book said it would be?  It is impossible to really learn accounting through a text book! There are way too many variables and circumstances that can impact a given situation.  Needless to say, I am not finding much inspiration from this blog post, and hopefully you are not all saying the same thing right now about mine

In writing all of this, it does get me thinking: are some of you so set in your ways of this how it is done that you are unable and unwilling to see that there could be a better, smarter, and faster way to do the task at hand?  For example, instead of having manual routings throughout the factory where you track your product, a barcode system is implemented so you can have updated, real-time data all the time.  Or maybe you have been in the profession for so long you cannot admit that you are unsure of how to do something, or that you just do not know.  You should know, you have done it for 25 years-right?  WRONG!  Just because you have done something for 25 years does not mean you are an expert who cannot learn something new. Conversely just because you have done something for 3 years does not mean you don’t have the knowledge. Many people are threatened by the fact that they may be exposed so instead of trying to solve a problem they do not understand, they live with it and try to hide it.  If someone like myself, a young professional, is capable of waltzing in and fixing the problem the exposure is even more embarrassing, I sure do not want that!  Think about what you are saying and what you are doing.  Why not make everything the best that it can be? Why not work to full capacity? What is there to be afraid of?  Are you the bottleneck of your department?

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