Kikelomo Limited manufactures three products K, T and F, using different quantities of the same resources. Budget information per unit is as follows: K T F ₦ ₦ ₦ Market selling price 1,800 2,520 3,000 Direct labour (₦140/hour) 280 560 700 Material A (₦60/kg) 300 240 420 Material B (₦120/kg) 480 720 600 Variable overhead (₦80/hour) 160 320 400 Fixed overhead 240 140 240 Total cost 1,460 1,980 2,360 Profit 340 540 640 Total budgeted sales units 500 800 1,600 The budgeted sales are for the month of June but do not include an order from a major customer to supply 400 units per month of each of the three products, at a discount of ₦200 per unit from the market selling price. During June, the management of Kikelomo Ltd anticipated that there will be a shortage of material B, and that only 17,500 kgs will be available. It is not possible for Kikelomo Ltd to hold inventory of any raw materials, work-in- progress or finished products. Required:
State THREE factors which may cause input materials to be a budget constraint and identify steps which may be taken to overcome this constraint.
Prepare calculations to show production that will maximise Kikelomo Ltd’s profit for June.
Kikelomo Ltd has now realised that the contract with the major customer does not have to be met in full for any of the three products. The customer will accept whatever Kikelomo is prepared to supply at the contracted 58 prices but they will charge a financial penalty if Kikelomo does not supply them in full in June. Based on this additional information: Calculate: The lowest value of the financial penalty that the major customer would need to insert in the contract to ensure that Kikelomo Ltd meets the order in full in June.
Now assume that the shortage of material B is expected to continue far beyond June and management of Kikelomo Ltd has decided to outsource the production of some of the products, advise the management of Kikelomo Ltd on the advantages and disadvantages of outsourcing.
Revise this question
Limiting factors: allocating a single scarce resource › LayoutsMake-or-buy and outsourcing decisions › Layouts for make-or-buy decisionsOne-off contracts, shutdown and further processing of joint products › Layouts for the three decisionsSuggested answer
a) The availability of materials may be a constraint when formulating the budget.
i) There may be a shortage of supply of materials e.g. where they are Imported and it is known that a bad harvest or political unrest will limit the total quantity available. ii) The company may have a limited quantity of specialist storage space available. For example raw material may require specially humidified storage or special storage container space where it is toxic or dangerous in nature. Such constraints may limit the overall amount of material which can be made available during the budget period. iii) The level of material losses in stores and in the production process may be unacceptably high. This will increase the total input materials required and could lead to a shortfall arising. iv) Seasonal material input v) Surge in demand vi) Storage facility and capacity vii) Transport system to move material viii) Price of related input material for substitute and complementary goods The steps: The company may attempt to minimise the effect of potential shortages by placing forward orders for materials. It may also consider possible substitute materials which are more readily available. Where storage space is a problem, the company may consider the renting of extra storage facilities. It may also wish to negotiate a ’just-in-time’ agreement whereby deliveries of material are guaranteed by suppliers to coincide with the forward production plan. In order to reduce the level of material losses, stores layout and control procedures should be reviewed. In the production process additional focus on the efficiency of machinery and the level of training of the work force should help reduce the level of material losses and hence the total material input required. 69
b) Computation of Production that maximises profit Product K T F N N N Selling Price 1,800 2,520 3,000 Less Variable cost: Direct labour (280) (560) (700) Material A (300) (240) (420) Material B (480) (720) (600) Variable overhead (160) (320) (400) Contribution/Unit 580 680 880 Ranking the products using contribution/kg of material B Kg of material B 4 6 5 Contribution/kg N145 N113.33 N176 Ranking 2nd 3rd 1st Use of material B 3,600kg 3,900kg 10,000kg Optimal Production 900 650 2,000
c) Producing with no special emphasis on special order K T F Contr./Unit N580 N680 N880 Normal Production 500 800 1,600 Unit of material B 4 6 5 2,000 4,800 8,000 = 14,800 Ranking 2nd 3rd 1st Bal. to be used for special Order 700kg 0 2,000kg = 2,700 Units to be produced under special order 175 units 400 units Normal contribution 580 x 500 =290,000 800 x 680 544,000 1,600 x 880 = 1,408,000 = N2,242,000 Special Order 175 x 380 = 66,500 - 400 x 680 = 272,000 N338,500 N356,500 N544,000 N1,680,000 = N2,580,500 70 Producing with Emphasis on Special order Optimal Production (units) 900 650 2,000 N Contribution/unit N580 N680 N880 Total Contribution N522,000 N442,000 N1,760,000 2,724,000 Less Discount N80,000 N80,000 N80,000 (240,000) N442,000 N362,000 N1,680,000 = 2,484,000 Financial Penalty N2,580,500 – N2,484,000 = N 96,500
d) Advantages of outsourcing:
i. It allows each party to focus on core competences. This should lead to improved quality of the final products produced by Alice. In addition, this should lead to improved efficiency in that part of the overall operations. ii. It should lead to improved services provided to customers, leading to an increase in customer satisfaction. This will assist in retaining existing customers and achieving repeat sales. iii. Outsourcing will mean that the amount of capital expenditure is reduced, as the company will no longer be required to invest in the plant and equipment needed to carry out the outsourced activity. iv. It should lead to less incidence of under-utilisation of assets. This will lead to greater efficiency, and will impact positively on a number of important performance measures (e.g. ROA, asset turnover, ROE, etc). v. It is possible, but by no means certain, that an activity can be provided by an outsourcer at lower cost than is possible in-house, as a result of the outsourcer’s ability to specialise. Disadvantages of outsourcing: i. Staff resistance: Members of staff, particularly those currently working in the activity to be outsourced, may be resistant, as they will fear that their jobs will be lost. ii. Loss of critical skill: In the medium to long term, the skills associated with the outsourced activity will be lost to the company. It is probable that replacing such skills could prove to be costly. If an inappropriate activity is outsourced, or the outsourcing initiative is unsuccessful, this could prove to be very costly. Once such skills have been lost, the supplier may seek to increase prices. In such circumstances there would be little option to accept the increased cost, unless an alternative supplier can be identified. 71
iii. Quality of the supplier: The success of an outsourcing initiative will be heavily influenced by the quality of the supplier. It may be difficult to identify a supplier who can provide the correct skills and meet the required specification. iv. Loss of confidential data: When an activity is outsourced, there is a danger that it allows competitors to obtain access to data which otherwise would remain in-house. This may lead to a commercial disadvantage. This is most likely to occur in the case of a product, and competitors may now be able to carry out a tear-down analysis more easily. v. Reputational problems: The most significant potential problem is the damage to reputation which may result if the supplier does not meet the required specification. vi. Outsourcing firm may turn to a competitor vii. Loss of managerial control viii. Failure to meet delivery targets
ix. Selection of vendors may take time and effort
Examiner’s report This is a compulsory question that tests candidates’ knowledge on how to handle limiting factor. Being a compulsory question, it was attempted by almost all the candidates. The candidates recorded an average performance. The pitfall is that most candidates failed to compute the financial penalty that will be expected when Kikelomo Ltd fails to supply the special order in full as well as failure to treat the discount as an attributable variable costs that only applies to the special order. Candidates are encouraged to study the Institute’s study manual when preparing for ICAN examinations. 72
Marking guide Marks a 3 factors that cause material input constraint 3 3 Steps to overcome them 3 6 b - Contribution per unit 1 ½ - Contribution per kg of material B 1 ½ - Ranking 1 ½ - Optimal Production 4 ½ 9 c Computation of lowest value of financial penalty (36 ticks at 16 mark) 6 d Advantages of outsourcing (2 points at 21/2 marks) 5 Disadvantage of outsourcing (2 points at 2 marks) 4 9 30