INGOT CAN COMPANY
Part I
A. Production Process Schematic:
1. Steel Sheets & Coating -->
2. Cylinder Production -->
3. Seal Side Seam & Bottom -->
4. Package Cans & Cut Tops
B. Production Costs and Drivers:
Cost Category Probable Driver Labor, Manpower, Supervisory Personnel Market Price of Labor, Manpower Availability,
Skill Levels, Experience Quotient, Specialists,
Ancillary Personnel, Quality Mix Maintenance, Repair and Prevention Replacement Part Costs, Frequency of Failure, Equipment Quality Electricity, Facilities, Insurance Power Rates, Quarterly Premiums, Rental Costs, Market Dynamics Depreciation, Amortization Not a Factor (Equipment nearly Obsolete) Test Materials Can-size Variety, Market price of Materials, Worker Efficiency Quotient Test Labor Labor Market for Specialists Miscellaneous Costs Market-Driven / Supply and Demand
C. Average Cost Per Case:
SUMMARY
Raw Material..........$117,000
Production Costs..... 108,832
Total....................... $225,832 / 100,000 = $2.26/Case
Production Cost Break-Down: (per 100,000 cases)
Labor........................................ $66,800
Maintenance ..................................1,069 --> (150,000 x 100,000 / 9,120,000) x .65 (Non-Idle)
Electricity, Facilities .......................4,276 --> (600,000 x 100,000/ 9,120,000) x .65 (Non-Idle)
Depreciation ........................................0 (fully depreciated equipment)
Test Material ...................................667--> (2000 x 20)/60
Test Labor ........................................200--> (25 x 2.4 x 20)/60
Other Costs................................. 36,000
TOTAL PRODUCTION COST......................................$108,832 per 100,000 cases +117,000 materials =$225,832
COST PER CASE = $2.26 (or 2.27)
D. Set-up Costs for each production run:
$2000 in materials + 2.4 hours x $25/hr. specialists = $2060, assuming one specialist.
2060 x 10 / 5 = $4,120 for a 20,000 case run.
E. Assuming 20,000 case production run costs are too high, Management could consider:
1. Renegotiating the purchase price of raw materials from suppliers
2. Rolling back worker salaries
3. Redesigning & streamlining the production process
4. Reducing the 35% idle time (6.0M actual production / 9.12M plant capacity),
through more efficient use of equipment and manpower.
5. Increasing overall monthly production to decrease costs per case.
Part II
A. Option 3 on Figure 3, below, is clearly the least expensive per 100,000 cases. The computations used to derive data appearing on Figure 3 are attached and are labeled "Part II, Section A."
Strategic Plan.................Cost for 6.3 M cases....... Cost for 100,000 cases ........Cost per case
Option 1 ........................$14,327,600.00................... $227,422 ..................................$2.27
Option 2 ..........................14,335,600.00..................... 227,549 ....................................2.27
Option 3 ..........................13,228,794.50 ....................210,000 .....................................2.10
FIGURE 3
The primary forces driving costs incurred for each step of the production process are as follows:
1. The price per case, for all three options, is determined by labor costs, equipment operation costs, down-time or idle-time (Options 1 & 2: 35% idle factor, whereas Option 3 has an approximate 10% down-time: see computations), depreciation for the third option if the lease does not absorb these costs, tests, set-ups, and other expenses. All cost categories are driven by market forces at time of production.
2. The rental or lease cost of equipment, under Options 2 and 3, is determined by market forces.
3. The demand for cans produced by INGOT is determined by market dynamics and establishes the overall 6.3 million cases per month figure, as projected by the case study author for the aging baby-boom generation. (Total 6.3M = 2.0 M (16 oz) + 2.0M (28 oz) + .8M (misc. sizes), 1.5M (individual serving size).
Figure 4, below, depicts a schematic representation of the components and factors driving production costs. All are determined by (1) local economic conditions,(2) supply and demand as well as by (3) labor market dynamics, and all pertain to the third Option, considered the most efficient and promising.
FOR OPTION 3
(The Preferred Strategy)
$2.10 price per case = rental costs + labor + maint + materials + facilities + misc.
FIGURE 4
B. There are, in fact, several options, other than the three described, that can be considered by Management. To reduce labor costs, and ideally material costs, it is possible to consider relocation of production facilities to either another city within the USA where costs and taxes would be lower, or to a third-world nation where labor and equipment expenses would result in a small fraction of present operating costs. Another possibility would be to increase sales through a strong marketing campaign, and perhaps double production to 12.6 million cases/month, thus realizing economies of scale and reducing price per unit.
C. Options 1 and 2 are clearly less efficient than the third option, because Option 3's new and flexible equipment, although more costly, provides much more acceptable customer satisfaction results. Immediate delivery is possible at lower cost per case (2.10 vs. 2.27). More supportive details are provided below.
Option 1, although functional on a short-term basis, is the poorest choice since equipment will be strained to its maximum capacity, delivery times will be delayed and additional set-up time, supervisory and maintenance costs will be incurred. Over a longer period of time, strategic costs would be much greater and, predictably, quality would suffer due to down-time, poor equipment performance and worker stress.
Option 2 improves productivity and flexibility to a limited degree, but costs per case remain constant. Although there are 3 operating production lines, the additional equipment requires conventional maintenance supervision, which Option 3 does not need.
D. As described in the case study, labor utilization and personnel functions, under the third option, would be restructured, resulting in considerable cost savings and improved efficiency. The actual production process would be streamlined due to the modern and flexible nature of the equipment. There would be modifications in the process, but also in the packaging, storage and shipping phases of the operation. Through enhanced worker productivity, material costs would be lower on average. While rental costs for flexible equipment seem higher, the actual cost per case is lower due to elimination of extra personnel, unnecessary under Option 3's more versatile system.
E. Due to increased production efficiency, far fewer employees would be required to operate and supervise the process. This would result in plant lay-offs and in a significant reduction in staffing. Labor unrest could ensue. Management must consider these implications when selecting one of the three options; but it seems, under Option 3, as if many of the affected employees could be reassigned or retrained as deemed useful or appropriate by Management, thus minimizing negative cultural or social impact.
Computations
Part II - Section A:
OPTION ONE
Can existing equipment process the extra 1.2 M cases of individual size cans if there is a decline in the 16 and 28 oz sizes? Yes! If $6000 is spent on add'l maintenance to keep machinery operating.
2.0M = 16 oz.
2.0M = 28 oz
0.8M = misc sizes
---------
4.8M = 1.5M indiv. size cases = TOTAL PRODUCTION: 6.3M cases/month.
Cost per case (carried over from Part I): 2.27 x 6.3 M = $14,301,000 production cost per month.
Additional Maintenance: = 6,000/month
$2000/test materials + 600/labor (24 hours x 25/hr) x 10 = 20,600/month
TOTAL: = $14,327,600/month
_____________________________________________________________________________
OPTION TWO
Cost per case (carried over from Part I): 2.27 x 6.3M = $14,301,000 production cost per month.
Lease cost per month (including maintenance): = 14,000/month
2000/test materials +600 labor (24hours x 25/hr) x 10 = 20,600/month
TOTAL: $14,335,600/month
________________________________________________________________________________
OPTION THREE
Calculations for revised cost per case:
NOTE: All cost elements for 'cost per case' as shown in 'Part I Computations' remain the same except LABOR, which is reduced as follows:
Supervisors 10,800 (unchanged).................... | Original Option 1 & 2 Labor Costs:
Operators 7,200 (reduced by 50%) ...............|............... 66,800
Packers 5,200 (reduced by 67%).................. | Revised: - 49,200
Warehouse 18,800 (unchanged) ....................| Savings: ...17 ,600 (per 100,000)
Janitorial 7,200 (unchanged) ..........................| SAVINGS PER CASE: $0.176
REVISED TOTAL: 49,200 Labor costs for 100,000 under Option 3.
NEW PRICE PER CASE CALCULATED: 2.27 minus savings/case (17.6 cents) = Approx $2.10.
Cost per case: : 2.10 x 6.3M = $13,198,752.00 production cost per month.
Lease cost per month (including maintenance): = 30,000.00/month
Labor (.17 hrs x 25/hr x 10) = 42.50/month
Total Production Costs for 6.3 M = 13,228,794.50/month
Calculations for 100,000 cases are simply derived by multiplying the cost/case (2.10) x 100,000, as shown on Figure 3. This applies, of course, to all three Options, although for Options 1 and 2, the cost per case differs.
~ ~ ~ ~