Activity-Based Costing/management and Its Implications For Operations Management
Activity-Based Costing/management and Its Implications For Operations Management
Activity-Based Costing/management and Its Implications For Operations Management
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Abstract
Activity-Based Costing/Management (ABC/M) is an Information System developed in the 1980s to overcome some of the limi- tations
of traditional cost accounting and to enhance its usefulness to strategic decision-making. In this paper, we show how an ABC/M system
can serve as a useful information system to support effective operations decision-making processes. We propose a conceptual framework,
Operations Hexagon, to discuss the managerial implications of an ABC/M system for various operations management decisions related to
product planning and design, quality management and control, inventory management, capacity management and work force management.
By viewing an ABC/M system as an enabler to improve the operations decision-making, we demonstrate that these systems enable an
operations manager to enhance the quality of the decision-making process.
2001 Elsevier Science Ltd. All rights reserved.
Keywords: Activity-based costing; Activity-based management; Operations management; Operations decision-making framework
1. Introduction
The present era of global competition, evolving technologies and information systems is leading companies
toward a renewed commitment to excellence in manufacturing. Increasing attention to the introduction of new
products, the quality of products and processes, the level of
inventories, and the improvement of workforce poli- cies
have helped companies to become world-class. Accurate
cost information is critical for every aspect of a business,
from its pricing policies to its product designs and
performance reviews. However, most companies are still
using the same traditional cost accounting systems that
were developed decades ago (Kaplan and Cooper, 1998).
For the last two decades, a new type of account- ing
system, Activity-Based Costing/Management (ABC/M),
has been gaining acceptance in the USA as well as in
Pacific Rim and European-based companies (Keegan and
Eiler, 1994). ABC/M systems represent a shift from a
strictly financial perspective to a 'whole- system'
perspective because they include both financial and nonfinancial data in its reporting. Rather than just
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the managerial implications of ABM systems implementations for operations managers. Finally, we conclude our
paper with some general guidelines and recommen- dations
to managers.
it may apply too much cost to one product and not enough
to another. An ABC/M system achieves improved
accuracy in the estimation of costs by using multiple cost
drivers to trace the cost of activities to those products
associated with the resources consumed by those activities
(Babad and Balachandran, 1993). To identify cost drivers,
the accountant must investigate the process of production to
determine what activities must be performed to produce a
product. Departmental man- agers can often identify these
activities. For example, in the purchasing department, a
portion of product cost might lie in the number of purchase
orders generated for each product. Manufacturing costs
might be based on the machine setups required for each
product run. Each of the activities that have an effect on the
cost of a pro- duct is a cost driver. Ideally, all cost drivers for
a product
are identified, but in practice the number of drivers is
usually limited to those that have the most significant
impact on cost.
Concisely, an ABC/M system development process
involves: (i) identifying resources (i.e. what is used to do
work); (ii) identifying resource drivers (i.e. what is
assigning the cost of the resources to activities based on
effort expended); (iii) identifying activities (i.e. work); (iv)
identifying activity drivers (assigning the cost of the
activities to products based on unique consumption
patterns); and (v) identifying the objects of work (to what or
for whom work is done) (Cokins, 1993).
2.1. Manufacturing changes that led to ABC/M system
During the last twenty years, manufacturing has dramatically changed. Whereas dramatic improvements have
been made in efficiencies and per-unit costs, profits have
shrunk; 'overhead' has risen dramatically, and busi- nesses
have seen fierce competition by foreign compa- nies, who
are responding to market needs better and fas- ter than ever
with high quality and innovative products. Manufacturing
today, with its focus on continual improvement, minimal
inventory and speedy turnaround, bears little resemblance to
manufacturing of yesterday, with its forced quality checks
on end-stage products, large inventory and slow response
to market needs and orders.
These changes in the environment have led managers to
search for explanations, which could account for why
increasing efficiencies was not increasing profitability and
competitiveness. Employing different methods of costing
products, accounting for increasing overhead costs, and
deciding which processes truly add value to a product or
service have become a necessity. Traditional management
accounting has been challenged to find ways to help
companies better understand and identify company
processes and costs.
Perhaps the rationale for the surge in interest in
ABC/M can best be seen by looking at some major criti-
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Fig. 2.
Next, we consider each of the outer segments individually to evaluate compatibility with the ABC/M concepts and demonstrate how many companies have successfully used ABC/M systems with varying
sophistication levels to address various OM decisions.
3.1. Product planning and design
An ABC/M system can provide useful insight into
product design decisions. In a firm, which manufactures
only one product, it is simple to assign costs to that product. However, in a firm with a complex product offer- ing,
cost assignment becomes more difficult. Product
complexity "results in high manufacturing overhead costs
incurred for such activities as supervision, quality control,
inspection, machine and tool maintenance, and production
control" (Cooper and Kaplan, 1991). Cost accounting's
allocation based on machine hours or direct labor hours does
not provide a clear picture of the true allocation of
resources. "Product costs thus become dis- torted, leading
to a biased analysis of design for manu- facturability,
product profitability, outsourcing, and make or buy
decisions" (Banker et al., 1990, p. 270). A clear example of
the impact that ABC data provide is with respect to the
decision of which product line to eliminate. For instance,
imagine a firm that makes pro- ducts to fill orders in large
quantities or small batches. Often small lot sizes appear
more profitable under tra- ditional cost accounting
systems, so the firm might decide to drop the products that
are produced in large lots to concentrate on the more
'profitable' niche pro- ducts.
However, ABC/M information may show that the small
lot product is actually much more expensive than estimated
because ABC data will include factors not usu- ally
considered, such as order processing. Relying on old
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tives on how to address these equipment needs are supported by ABC data.
Traditional cost accounting may provide misleading
information regarding the costs of equipment that bias
decisions about upgrading or replacing equipment. New
technologies are often expensive, and many companies
require detailed justification proposals for new purchases. Preparing comparisons of current versus pro- posed
equipment becomes clearer using ABC/M sys- tems.
A survey cosponsored by the National Association of
Accountants and computer-aided Manufacturing International concluded that even though most US firms attach
a critical importance to the strategic justification of
advanced manufacturing technologies, they fail to
explicitly incorporate the firm's strategy into the investment analysis. Brimson (1989) suggested an activity- based
investment analysis system that analyzes in detail the
impact of a new technology on the cost, performance, and
interdependence of key activities. The system pro- vides a
mechanism to systematically decompose the company
goals and objectives into a base set of activities that are
impacted by the investment.
Thus, Brimson (1989) argued that the activities pro- vide
a consistent basis for analyzing investment and monitoring
the actual results through an ABC/M system.
3.6. Work force management
The ABC process can have a significant impact on a
firm's employees, particularly in areas of employee
empowerment and accountability, roles and responsibilities, and performance measures. (Turney, 1993) ABC
starts with identifying activities that are performed in a
firm. An excellent starting point for gathering ABC
information is the front-line employee.
3.6.1. Empowerment and accountability
ABC takes information that was previously couched in
pure financial terms and translates it into terms that relate
to specific activities. With ABC, performance measures
can be described in meaningful terms. An employee
becomes aware of how his activities contribute to the firm's
financial performance. ABC gives the employee the tools
he needs to evaluate not only how he is currently
contributing, but how he might improve his performance to
increase that contribution.
"Operators, who know the full cost of the raw
materials and the full cost of reworking defective units, are
able to decide whether to scrap bad production or rework
it, without intervention by more senior manage- ment."
(Armitage and Russell, 1993, p. 7) Empowering employees
to make these types of decisions can help prevent costly
reworking or poor quality product. It can also have an
impact on employee commitment and mor- ale.
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4. Conclusion
Traditional cost accounting methods, which allocate
overhead costs on the basis of one driver (e.g. direct labor
or machine hours) are inaccurate and misleading as these
methods often allocate too much cost to one product and
not enough to another. To address this prob- lem, activitybased accounting was developed to provide a means to
create a more accurate representation of how activities
performed in the creation of a product or ser- vice actually
impact its cost. ABC/M systems examine processes or
activities to determine their effects on costs. An ABC/M
system can be used by any firm which is able to identify
activities that drive costs and allocate those costs to its
particular products or services. Rather than allocating
overhead on the basis of one variable, such as direct labor,
ABC/M systems use multiple cost drivers to present a more
accurate foundation for over- head allocation. Cost drivers
are identified by actually reviewing the entire production
process to uncover what activities cause those costs. ABC/M
systems can be inte-
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Mahesh Gupta ia an associate professor in the Department of Manage- ment,
University of Louisville. He obtained his MCom from the University
of Jammu, India, his MSc from the University of Manitoba, Canada, and
his PhD from the University of Louisville, USA. Dr Gupta has published in
numerous journals including International Journal of Operations and
Production Management, International Journal of Production Research,
European Journal of Operational Research, and Production and Inventory
Management. Dr Gupta is a member of APICS, DSI, INFORMS, ASQ, and
POMS.
Karen Galloway was a graduate student at the Business School at the time the
research presented in this article was conducted.