Destin Company produces water control valves, made of brass, that it sells primarily to builders for use in commercial real estate construction. These valves must meet rigid specifications (i.e., the quality tolerance is small). Valves that, upon inspection, get rejected are returned to the Casting Department; that is, they are returned to stage 1 of the four-stage manufacturing process. Rejected items are melted and then recast. As such, no new materials in Casting are required to rework these items. However, new materials must be added in the Finishing Department for all reworked valves. As the cost accountant for the company, you have prepared the following cost data regarding the production of a typical valve: Cost Casting Finishing Inspection Packing Total Direct materials $ 260 $ 10 $ 0 $ 10 $ 280 Direct labor 145 155 45 45 390 Variable manufacturing overhead 190 185 40 40 455 Allocated fixed overhead 105 115 140 110 470 $ 700 $ 465 $ 225 $ 205 $ 1,595 The company, spurred by intense price pressures from foreign manufacturers, recently initiated a number of quality programs. As a result, the rejection rate for valves has decreased from 8.1% to 5.9% of annual output (equal in total to 19,000 units). The reduction in reject rates has enabled the company to reduce its inventory holdings from $600,000 to $350,000. Destin estimates that the annual financing cost associated with inventory holdings is 11%. Required: What are the estimated manufacturing cost savings per year associated with the reduction in rework costs? What are the annual financing cost savings associated with the reduction in inventory holdings? Provide a dollar estimate of the total annual cost savings associated with the recently enacted quality improvements. Note: Do not round intermediate calculations.
Destin Company produces water control valves, made of brass, that it sells primarily to builders for use in commercial real estate construction. These valves must meet rigid specifications (i.e., the quality tolerance is small). Valves that, upon inspection, get rejected are returned to the Casting Department; that is, they are returned to stage 1 of the four-stage manufacturing process. Rejected items are melted and then recast. As such, no new materials in Casting are required to rework these items. However, new materials must be added in the Finishing Department for all reworked valves. As the cost accountant for the company, you have prepared the following cost data regarding the production of a typical valve:
| Cost | Casting | Finishing | Inspection | Packing | Total |
|---|---|---|---|---|---|
| Direct materials | $ 260 | $ 10 | $ 0 | $ 10 | $ 280 |
| Direct labor | 145 | 155 | 45 | 45 | 390 |
| Variable manufacturing |
190 | 185 | 40 | 40 | 455 |
| Allocated fixed overhead | 105 | 115 | 140 | 110 | 470 |
| $ 700 | $ 465 | $ 225 | $ 205 | $ 1,595 |
The company, spurred by intense price pressures from foreign manufacturers, recently initiated a number of quality programs. As a result, the rejection rate for valves has decreased from 8.1% to 5.9% of annual output (equal in total to 19,000 units). The reduction in reject rates has enabled the company to reduce its inventory holdings from $600,000 to $350,000. Destin estimates that the annual financing cost associated with inventory holdings is 11%.
Required:
- What are the estimated
manufacturing cost savings per year associated with the reduction in rework costs? - What are the annual financing cost savings associated with the reduction in inventory holdings?
- Provide a dollar estimate of the total annual cost savings associated with the recently enacted quality improvements.
Note: Do not round intermediate calculations.
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