JIT Cost
JIT Cost
The JIT control system is based on a philosophy that inventory is undesirable. Subscribers to the JIT philosophy
believe inventory reductions expose organizational problems and inefficiencies. These problems and inefficiencies
may not be brought to management's attention if inventories are not pushed to lower and lower levels. They would
remain hidden and undetectable at higher levels of inventory.
JIT production control systems foster automation and reduced levels of inventory. Consequently, raw material
inventories and direct labor costs may be too small to warrant separate cost pools-they can be combined with
other cost pools.
Additional adjustments may be necessary to accommodate standard costs, which are constantly adjusted to reflect
the latest technological changes in production methods. Also, more costs could be traced to specific products and
fewer costs would have to be allocated.
JIT production control systems foster automation and reduced levels of inventory. Consequently, raw material
inventories and direct labor costs may be too small to warrant separate cost pools-they can be combined with
other cost pools.
Additional adjustments may be necessary to accommodate standard costs, which are constantly adjusted to reflect
the latest technological changes in production methods. Also, more costs could be traced to specific products and
fewer costs would have to be allocated.
The JIT manufacturer will limit the number of suppliers to a few. Long-term contracts are entered into with
suppliers. Suppliers' raw material must be top quality with no defects.
Small quantities of raw material are delivered frequently and little or no raw material is maintained by the buyer.
Suppliers must be located close enough to the JIT buyer to deliver small quantities very quickly. The supplier
must agree to providing a top-quality product to its JIT customer.
The geographical proximity is important to minimize shipping and handling costs of supplies and materials.
Geographical proximity also facilitates frequent communication and joint planning between a supplier and
customer.
Push System: In a push system, releases are scheduled. So, throughput is determined by an exogenously set
release rate (given by the Master Production Schedule). Since the releases are linked to orders (or forecasts), a
push system is controlled by upstream information and is inherently make-to-order. In terms of our nomenclature,
open lines are push systems because they have no endogenous restriction on releases to the line.
Pull System: In a pull system, releases are authorized. That is, there is an endogenous signal based on system
status that determines whether a release is allowed or not. In particular, the system status that triggers releases is
based on stock voids, which means that a pull system is controlled by downstream information and is
inherently make-to-stock. In our nomenclature, closed lines are pull systems, because buffer spaces act as stock
voids to trigger releases.
Larger levels of inventory exist by design in push production control systems. The inventory buffers permit lower
levels of communication between business segments, permit longer production runs, and protect the firm from
environmental uncertainties and unforeseen interruptions in production or supplies.
Kaizen and Kanban are each Japanese manufacturing concepts that have been popularized all all over the world.
Kaizen is a Japanese term that stands for “improvement”. It is a strategy that believes that alter brings
improvement. It centers on practices that bring about continuous improvement. Kanban is also a Japanese term
however it indicates “signboard”. It truly is a idea that aids in the implementation of lean manufacturing and just
in time (JIT) production. Kanban is more like a sophisticated scheduling system in general. It regulates demand
and supply. Its implementation is currently limited to achieving lean management and JIT production.
Economic order quantity (EOQ) is that size of the order which gives maximum economy in purchasing
any material and ultimately contributes towards maintaining the materials at the optimum level and at the
minimum cost.
In other words, the economic order quantity (EOQ) is the amount of inventory to be ordered at one time for
purposes of minimizing annual inventory cost.
The quantity to order at a given time must be determined by balancing two factors: (1) the cost of possessing or
carrying materials and (2) the cost of acquiring or ordering materials. Purchasing larger quantities may decrease
the unit cost of acquisition, but this saving may not be more than offset by the cost of carrying materials in stock
for a longer period of time.
Obsolescence of stocks.
The different formulas have been developed for the calculation of economic order quantity (EOQ). The following
formula is usually used for the calculation of EOQ.
*=×
Example:
Pam runs a mail-order business for gym equipment. Annual demand for the TricoFlexers is 16,000. The annual
holding cost per unit is P2.50 and the cost to place an order is P50.
The purpose of the EOQ model is to identify the least cost quantity of a material to be purchased at each order
point. The model explicitly considers the carrying and ordering costs and identifies the purchase quantity that
minimizes the total of these costs.
Target Costing vs kaizen
Target costing is considered a procedural approach that is used to determine a maximum allowable cost for a
product, while kaizen costing is a mandate to reduce costs, increase product quality, and/or improve production
process through continuous improvement. Target costing has a large potential for cost reduction in life-long
product cost because these costs are embedded in the product during design and development. Kaizen costing has
limited potential in cost reduction of existing products, but may be useful in target costing in the future.
This is that level of materials at which a new order for supply of materials is to be placed. In other words, at this
level a purchase requisition is made out. This level is fixed somewhere between maximum and minimum levels.
Order points are based on usage during time necessary to requisition order, and receive materials, plus an
allowance for protection against stock out.
The order point is reached when inventory on hand and quantities due in are equal to the lead time usage quantity
plus the safety stock quantity.
The following two formulas are used for the calculation of reorder level or point.
Ordering point or re-order level = Maximum daily or weekly or monthly usage × Lead time
The above formula is used when usage and lead time are known with certainty; therefore, no safety stock is
provided. When safety stock is provided then the following formula will be applicable:
Ordering point or re-order level = Maximum daily or weekly or monthly usage × Lead time + Safety stock
Examples:
Example 1:
Calculation:
Ordering point = Ordering point or re-order level = Maximum daily or weekly or monthly usage × Lead time
= 800 × 30
= 24,000 units
Example 2:
Minimum usage
20 units per week each
Calculation:
Ordering point or re-order level = Maximum daily or weekly or monthly usage × Maximum re-order period
A: 60 × 5 = 300 units
B: 60 × 4 = 240 units
The minimum level or minimum stock is that level of stock below which stock should not be allowed to fall. In
case of any item falling below this level, there is danger of stopping of production and, therefore, the management
should give top priority to the acquisition of new supplies.
Formula: Minimum level or minimum limit can be calculated by the following formula or equation:
Minimum limit or level = Re-order level or ordering point – Average or normal usage × Normal re-order period
Minimum limit or level = Re-order level or ordering point – Average usage for Normal period
Example:
Calculation:
Ordering point or re-order level = Maximum daily or weekly or monthly usage × Maximum re-order
= 130 × 30
= 3,900 units
Minimum limit or level = Re-order level or ordering point – Average or normal usage × Normal re-order period
1150 units
*(25 + 30 ) / 2
The maximum stock limit is upper level of the inventory and the quantity that must not be exceeded without
specific authority from management. In other words, the maximum stock level is that quantity of material above
which the stock of any item should not normally be allowed to go. This level is fixed after taking into account
such factors as: capital, rate of consumption of materials, storage space available, insurance cost, risk of
deterioration and obsolescence and economic order quantity.
Formula: Maximum level or maximum limit can be calculated by the help of following formula:
Maximum limit or level = Re-order level or ordering point – Minimum usage × Minimum re-order period +
Economic order quantity
Example:
In order to calculate maximum limit of stock we must calculate re-order point or re-order level first.
Ordering point or re-order level = Maximum daily or weekly or monthly usage × Maximum re-order
= 130 × 30
= 39,000 units
Calculation:
Maximum limit or level = Re-order level or ordering point – Minimum quantity used in re-order period usage +
Economic order quantity
= 7150 units
Multiple Choice Identify the choice that best completes the statement or answers the question.
D 1. If 500 units are produced per day and 2,000 units are in process at any time, the throughput time is:
SUPPORTING CALCULATION:
2,000
= 4 days
500
D 2. In a JIT system, if the rate of output is doubled while the number of units in process is cut in half, then the
speed of the system has been:
B. doubled D. quadrupled
B 3. If the annual carrying cost percentage is 30% and average work in process is P300,000 and management
plans to use JIT to double the velocity of work in process without changing total annual output, the savings
in annual carrying costs will be:
A. P90,000 C. P150,000
B. P45,000 D. P180,000
SUPPORTING CALCULATION:
A 4. If Step 1 in a production process processes each unit and sends it to await Step 2, and 500 units are waiting
between Steps 1 and 2, how many defective units might Step 1 produce before the problem is detected in
Step 2?
A. 500 C. 250
C 5. Assume that a company plans a reduction in work in process levels of 50% and has an annual inventory
carrying cost of 20% and a past average cost of work in process of P75,000. The 50% reduction in work in
process would be expected to produce annual savings of:
A. P37,500 C. P7,500
B. P15,000 D. P3,750
SUPPORTING CALCULATION:
A. P37,500 C. P30,000
B. P15,000 D. P7,5000
SUPPORTING CALCULATION:
B 7. Beta Company has an average peso loss per defective unit of P25, a planned reduction in number of
defective units produced per out-of-control condition of 5, and the number of out-of-control conditions not
discovered immediately is 250. The expected savings in cost of defects would be:
A. P1,250 C. P6,250
B. P31,250 D. P125
SUPPORTING CALCULATION:
B 8. Beta Company has an average peso loss per defective unit of P25, a planned reduction in work in process
levels of 50%, and an average number of units in work in process per station of 100. Assume that the total
number of instances in which some work station goes out of control limits and produces defects is expected
to be 500 annually and that in half those instances the out-of-control condition is not discovered
immediately and enters 10% of the units produced. The expected annual savings in cost of defective units
would be:
A. P1,250 C. P6,250
B. P31,250 D. P125
SUPPORTING CALCULATION:
B 9. Cheeta Company has materials cost in the June 1 Raw and In Process of P10,000, materials received during
June of P205,000 and materials cost in the June 30 Raw and In Process of P12,500. The amount to be
backflushed from Raw and In Process to Finished Goods at the end of June would be:
A. P215,000 B. P202,500
C. P207,500 D. P217,500
D 10. In backflush costing, if the conversion cost in the Raw and In Process was P500 on July 1 and P1,000 on July
31, the account to be credited at the end of July for the P500 increase would be:
A 11. In backflush costing, if the conversion cost in Raw and In Process was P1,000 on March 1 and P400 on March
31, the account to be credited for the P600 decrease would be: