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$5,640,000
142,500
10,500
$1,917,600
42,000
240,000
$5,793,000
(2,199,600)
$3.593,400
(980,000)
$2,613,400
========
a. Compute the total pre-tax profit lost by the company in its first year of
operations by selling defective units as seconds or as scrap rather than
selling the units through regular channels.
b. Compute the total failure cost for the company in its first year.
c. Compute total quality cost incurred by the company in its first year.
d. What evidence indicates that the firm is dedicated to manufacturing and
selling high-quality products?
Answer to the Problem 17.45 Cost of Quality
45.a. Price for scrapped units = $10,500 300 = $35
Price for good units = $5,640,000 28,200 = $200
Profit lost = 300 units ($200 - $35) = 300 $165 = $49,500
Price for seconds = $142,500 1,500 = $95
Profit lost = 1,500 units ($200 - $95) = 1,500 $105 = $157,500
$207,000
$240,600
240,000
$480,600
(8,400)
42,000
$240,600
d. Although the companys failure costs were slightly more than its
prevention and appraisal costs, the majority of the failure costs were
internal. Thus, Burtram Ltd. caught most of the problems prior to
defective products being sold to customers. Also, there were no
product returnseven of the reworked seconds. The large expenditure
on prevention is an investment that should yield fewer failure costs in
future periods.
Problem 17.46 Cost of Quality
During 2008 (the first year of operations), Sorkowsky Company produced 19,900
portable navigation systems; of these, 500 were found defective by quality
appraisers. Three hundred of the defective units were reworked and sold through
regular channels at the original price; the rest were sold as seconds without
rework, (The uncorrected defects did not pose a hazard to customers; it was a
voice flaw which made the units sometimes sound as if they were yelling at the
users.) The navigation systems are sold with a two-year warranty; seconds have
a six month warranty.
In 2008, Sorkowsky Company spent $225,000 as prevention measures and
$98,000 on appraisal. Following is the partnerships 2008 income statement,
which appropriately does not reflect any income taxes:
SORKOWSKY COMPANY
Income Statement
For Year Ended December 31, 2008
Regular sales (19,700 units)
$5,122,000
Sales of seconds (200 units)
28,000
Cost of goods sold
Original production costs
$1,600,000
Rework costs (300 units)
10,500
Prevention and appraisal costs
323,000
$5,150,000
(1,933,500)
$3,216,500
(1,200,000)
$2,016,500
=========
a. Compute the total profit lost by Sorkowsky Company in its first year of
operation by selling defective units as seconds rather than reworking them
and selling them at the regular price.
b. Compute the companys total failure cost in 2008.
c. Compute the companys total quality cost in 2008.
d. Assume that selling and administrative expenses include $150,000 to
operate a customer complaint center. How should this cost be categorized
relative to quality costs?
e. Are the costs included in the 2008 income statement completely reflective
of Sorkowskis quality costs?
Answer to the Problem 17.45 Cost of Quality
46.a. Price for seconds = $28,000 200 = $140
Price for good units = $5,122,000 19,700 = $260
Production costs = $1,600,000 19,900 = $80.40 (rounded)
Profit lost = 200 units x ($260 - $140) = 200 $120 = $24,000
b. Profit lost
Less avoided rework cost on seconds
[200 units ($10,500 300) = 200 $35
Profit lost
Rework cost incurred
Total failure cost
c.
$24,000
(7,000)
$17,000
10,500
$27,500
$ 27,500
323,000
$350,500
$15,000
50,000
32,000
Appraisal Costs
Quality inspections
Test equipment
Procedure verifications
$18,000
14,000
9,000
$6,500
2,100
$9,500
7,600
Managers were also aware that in 2008, 250 of the 8,000 carts produced had to
be sold as seconds. These 250 carts were sold for $80 less profit per unit than
good carts. Also, the company incurred the rework costs amounting to $6,000
to sell 200 other carts through regular market channels.
a. Using these data, calculate Richfield Corp.s 2008 expense for the following:
1. Lost profit from the 250 units
2. Total failure cost
3. Total quality cost be reflected in quality cost?
b. Assume that the company is considering expanding its existing 5-year
warranty to a seven-year warranty in 2009. How should such a change be
reflected in quality costs?
Answer to the Problem 17.47 Cost of Quality
47.a. 1. Lost profits 250 $80 = $20,000
4
$20,000
6,000
6,500
2,100
9,500
7,600
$51,700
$15,000
50,000
32,000
$ 97,000
$18,000
14,000
9,000
41,000
51,700
$189,700
$10,000
30,000
22,000
Appraisal Costs
Quality inspections
Recording defects
Procedure verifications
$12,000
9,000
6,000
$4,500
1,400
$6,400
5,100
You also determined that 1,200 of the 100,000 tanks made in 2008 had to be
sold as scrap for $70 less profit per tank than the nondefective tanks. Smooth
Sailing also incurred $4,000 of rework costs that had been buried in overhead (in
addition to the failure costs listed) in producing the tanks sold at the regular price.
a. Smooth Sailings management has asked you to determine the 2008
costs of the following:
1. Lost profit from scrapping the 1,200 units.
2. Total failure cost.
3. Total quality cost.
b. Assume that the company is considering expanding its existing full 2-year
warranty to a full 3-year warranty in 2009. How should such a change be
reflected in quality costs?
Answer to the Problem 17.48 Cost of Quality
48.
$ 84,000
9,900
11,500
$105,400
$105,400
62,000
27,000
$194,400
reduce warranty claims and these appraisal efforts will, per se,
increase appraisal costs.