Mercury, Incorporated, produces cell phones at its plant in Texas. In recent years, the company's market share has been eroded by stiff competition from overseas. Price and product quality are the two key areas in which companies compete in this market. A year ago, the company's cell phones had been ranked low in product quality in a consumer survey. Shocked by this result, Jorge Gomez, Mercury's president, initiated an intense effort to improve product quality. Gomez set up a task force to implement a formal quality improvement program. Included on this task force were representatives from the Engineering, Marketing, Customer Service, Production, and Accounting departments. The broad representation was needed because Gomez believed that this was a companywide program and that all employees should share the responsibility for its success.

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Mercury, Incorporated, produces cell phones at its plant in Texas. In recent years, the company's market share has been eroded by stiff
competition from overseas. Price and product quality are the two key areas in which companies compete in this market.
A year ago, the company's cell phones had been ranked low in product quality in a consumer survey. Shocked by this result, Jorge
Gomez, Mercury's president, initiated an intense effort to improve product quality. Gomez set up a task force to implement a formal
quality improvement program. Included on this task force were representatives from the Engineering, Marketing, Customer Service,
Production, and Accounting departments. The broad representation was needed because Gomez believed that this was a
companywide program and that all employees should share the responsibility for its success.
After the first meeting of the task force, Holly Elsoe, manager of the Marketing Department, asked John Tran, production manager,
what he thought of the proposed program. Tran replied, "I have reservations. Quality is too abstract to be attaching costs to it and then
to be holding you and me responsible for cost improvements. I like to work with goals that I can see and count! I'm nervous about
having my annual bonus based on a decrease in quality costs; there are too many variables that we have no control over."
Mercury's quality improvement program has now been in operation for one year. The company's most recent quality cost report is
shown below.
Prevention costs:
Machine maintenance
Training suppliers
Quality circles
Total prevention cost
Appraisal costs:
Incoming inspection
Final testing
Total appraisal cost
Internal failure costs:
Rework
Scrap
Total internal failure cost
External failure costs:
Mercury, Incorporated
Quality Cost Report
(in thousands)
Warranty repairs.
Customer returns.
Total external failure cost
Total quality cost
Total production cost
Prevention costs:
Machine maintenance
Training suppliers
Quality circles
Total prevention costs
Appraisal costs:
Incoming inspection
Final testing
Total appraisal costs
Internal failure costs:
Rework
Scrap
Total internal failure costs
External failure costs:
As they were reviewing the report, Elsoe asked Tran what he now thought of the quality improvement program. Tran replied. "I'm
relieved that the new quality improvement program hasn't hurt our bonuses, but the program has increased the workload in the
Production Department. It is true that customer returns are way down, but the cell phones that were returned by customers to retail
outlets were rarely sent back to us for rework."
Warranty repairs
Customer returns
Total external failure costs
Total quality cost
Total production cost
Required:
1. Expand the company's quality cost report by showing the costs in both years as percentages of both total production cost and total
quality cost.
Note: Round your percentage answers to 1 decimal place (i.e 0.1234 should be entered as 12.3).
Amount
$
310
9
21
340
60
150
210
Last Year This Year
$310
$ 120
9
10
21
340
150
62
212
60
150
210
72
272
344
$ 1,106
$
4,210
150
62
212
70
200
30
96
126
70
40
110
72
272
344
$ 1,106
$ 4,210 $ 4,610
Last Year
Percentage of
Total Production
Cost
30
80
110
$ 546
Mercury, Incorporated
Quality Cost Report
(in thousands)
Percentage of
Total Quality
Cost
Amount
$
120
10
70
200
30
96
126
70
40
110
30
80
110
$
546
$ 4,610
This Year
Percentage of
Total Production
Cost
Percentage of
Total Quality
Cost
Transcribed Image Text:Mercury, Incorporated, produces cell phones at its plant in Texas. In recent years, the company's market share has been eroded by stiff competition from overseas. Price and product quality are the two key areas in which companies compete in this market. A year ago, the company's cell phones had been ranked low in product quality in a consumer survey. Shocked by this result, Jorge Gomez, Mercury's president, initiated an intense effort to improve product quality. Gomez set up a task force to implement a formal quality improvement program. Included on this task force were representatives from the Engineering, Marketing, Customer Service, Production, and Accounting departments. The broad representation was needed because Gomez believed that this was a companywide program and that all employees should share the responsibility for its success. After the first meeting of the task force, Holly Elsoe, manager of the Marketing Department, asked John Tran, production manager, what he thought of the proposed program. Tran replied, "I have reservations. Quality is too abstract to be attaching costs to it and then to be holding you and me responsible for cost improvements. I like to work with goals that I can see and count! I'm nervous about having my annual bonus based on a decrease in quality costs; there are too many variables that we have no control over." Mercury's quality improvement program has now been in operation for one year. The company's most recent quality cost report is shown below. Prevention costs: Machine maintenance Training suppliers Quality circles Total prevention cost Appraisal costs: Incoming inspection Final testing Total appraisal cost Internal failure costs: Rework Scrap Total internal failure cost External failure costs: Mercury, Incorporated Quality Cost Report (in thousands) Warranty repairs. Customer returns. Total external failure cost Total quality cost Total production cost Prevention costs: Machine maintenance Training suppliers Quality circles Total prevention costs Appraisal costs: Incoming inspection Final testing Total appraisal costs Internal failure costs: Rework Scrap Total internal failure costs External failure costs: As they were reviewing the report, Elsoe asked Tran what he now thought of the quality improvement program. Tran replied. "I'm relieved that the new quality improvement program hasn't hurt our bonuses, but the program has increased the workload in the Production Department. It is true that customer returns are way down, but the cell phones that were returned by customers to retail outlets were rarely sent back to us for rework." Warranty repairs Customer returns Total external failure costs Total quality cost Total production cost Required: 1. Expand the company's quality cost report by showing the costs in both years as percentages of both total production cost and total quality cost. Note: Round your percentage answers to 1 decimal place (i.e 0.1234 should be entered as 12.3). Amount $ 310 9 21 340 60 150 210 Last Year This Year $310 $ 120 9 10 21 340 150 62 212 60 150 210 72 272 344 $ 1,106 $ 4,210 150 62 212 70 200 30 96 126 70 40 110 72 272 344 $ 1,106 $ 4,210 $ 4,610 Last Year Percentage of Total Production Cost 30 80 110 $ 546 Mercury, Incorporated Quality Cost Report (in thousands) Percentage of Total Quality Cost Amount $ 120 10 70 200 30 96 126 70 40 110 30 80 110 $ 546 $ 4,610 This Year Percentage of Total Production Cost Percentage of Total Quality Cost
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