Explain how operations would have differed in Year 2 and Year 3 if the company had been using Lean Production, with the result that ending inventory was zero Starfax, Inc., manufactures a small part that is widely used in various electronic products such as homecomputers. Operating results for the first three years of activity were as follows (absorptioncosting basis):Year 2$ 800,000 $ 640,000 $800,000400,000Year 1Year 3SalesCost of goods sold580,000620,000Gross marginSelling and administrative expenses220,000190,000240,000180,000180,000190,000Net operating income (loss)$ 30,000 $ 60,000 $(10,000)In the latter part of Year 2, a competitor went out of business and in the process dumped a large numberof units on the market. As a result, Starfax's sales dropped by 20% during Year 2 even though productionincreased during the year. Management had expected sales to remain constant at 50,000 units; theincreased production was designed to provide the company with a buffer of protection against unexpectedspurts in demand. By the start of Year 3, management could see that inventory was excessive and thatspurts in demand were unlikely. To reduce the excessive inventories, Starfax cut back production duringYear 3, as shown below:Year 2Year 150,00050,00060,00040,000Year 340,00050,000Production in unitsSales in unitsAdditional information about the company follows:a. The company's plant is highly automated. Variable manufacturing expenses (direct materials, directlabor, and variable manufacturing overhead) total only $2 per unit, and fixed manufacturing overheadexpenses total $480,000 per year.b. Fixed manufacturing overhead costs are applied to units of product on the basis of each year'sproduction. That is, a new fixed manufacturing overhead rate is computed each year.c. Variable selling and administrative expenses were $1 per unit sold in each year. Fixed selling andadministrative expenses totaled $140,000 per year.d. The company uses a FIFO inventory flow assumption.Starfax's management can't understand why profits doubled during Year 2 when sales dropped by 20% andwhy a loss was incurred during Year 3 when sales recovered to previous levels. Ending inventory units2000010000200000 | 140000Ending inventory value underabsorption costingVariable manufacturing cost per unit222Ending inventory value under variablecosting4000020000Cost of production carried over to nextmonthunder absorption costing160000120000

With lean production, inventory production would have been planned so that little or no inventory…

Starfax, Inc., manufactures a small part that is widely used in various electronic products such as home computers. Operating results for the first three years of activity were as follows (absorption costing basis): Year 2 $ 800,000 $ 640,000 $800,000 400,000 Year 1 Year 3 Sales Cost of goods sold 580,000 620,000 Gross margin Selling and administrative expenses 220,000 190,000 240,000 180,000 180,000 190,000 Net operating income (loss) $ 30,000 $ 60,000 $(10,000) In the latter part of Year 2, a competitor went out of business and in the process dumped a large number of units on the market. As a result, Starfax's sales dropped by 20% during Year 2 even though production increased during the year. Management had expected sales to remain constant at 50,000 units; the increased production was designed to provide the company with a buffer of protection against unexpected spurts in demand. By the start of Year 3, management could see that inventory was excessive and that spurts in demand were unlikely. To reduce the excessive inventories, Starfax cut back production during Year 3, as shown below: Year 1 50,000 50,000 Year 2 60,000 40,000 Year 3 40,000 50,000 Production in units Sales in units Additional information about the company follows: a. The company's plant is highly automated. Variable manufacturing expenses (direct materials, direct labor, and variable manufacturing overhead) total only $2 per unit, and fixed manufacturing overhead expenses total $480,000 per year. b. Fixed manufacturing overhead costs are applied to units of product on the basis of each year's production. That is, a new fixed manufacturing overhead rate is computed each year. c. Variable selling and administrative expenses were $1 per unit sold in each year. Fixed selling and administrative expenses totaled $140,000 per year. d. The company uses a FIFO inventory flow assumption. Starfax's management can't understand why profits doubled during Year 2 when sales dropped by 20% and why a loss was incurred during Year 3 when sales recovered to previous levels.