scholarly journals ASSESSMENT THE UNUSED CAPACITY USING TIME DRIVEN ACTIVITY BASED COSTING IN AUTOMOTIVE MANUFACTURING INDUSTRY

2020 ◽  
Vol 4 (1) ◽  
pp. 82-94
Author(s):  
N.F.A. Ghani ◽  
S.N.A.M. Zaini ◽  
M.Y. Abu
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Investment Strategy ◽  
Cost Driver ◽  
Actual Condition ◽  
Activity Based Costing ◽  
Automotive Manufacturing ◽  
Cost Rate ◽  
Capacity Cost

Automotive Manufacturing Industry usually known implementing all six sigma method and lean manufacturing. However, actual practicality in the world of manufacturing, there are a lot of factors contributes that become the challenge to the ideal of lean production line. Not exclude those factors, there is no methods to identify the possible lost cost by the factors. This research is to identify the used-and un-used capacity exist in production line that considering factors affecting the production line at real time. Time-driven activity-based costing (TDABC) is identified as one of the powerful tools to analyze the actual condition of production. Cost-driver rate is defined in Phase 3 where the highest capacity cost rate calculated is RM0.67 per minutes which involving Station 3, Station 5, Station 7 and Station 8. The least capacity cost rate is RM0.33 per minutes recorded by Station 0(Preparation), Station 2 and Station 6. Ten time equations for each station at trim line is developed. During the development of time equation, criticality of Station 7 when it became the only station affected with all thirteen factors listed can be seen as station that needed focus for improvement or target for lean manufacturing. In regards of the relevancy of applying Time-Driven Activity-Based Costing, as a whole, TD-ABC can be used to identify the estimation capacity used either over or under-used. Not only un-used capacity is identified, but result shows Station 0 is over-used by 2932 minutes equals to RM967.56. Therefore, based on the result obtained, station with over-used capacity and several stations with under-used capacity gives a clear overview to the management of the company for better investment strategy.

A Case Study on the Un-Used Capacity Assessment Using Time Driven Activity Based Costing for Magnetic Components

2020 ◽  
Vol 6 (1) ◽  
pp. 18-39
Author(s):  
Areena Zaini ◽  
Haryantie Kamil ◽  
Mohd Yazid Abu
Keyword(s):  
Historical Data ◽  
Manufacturing Sector ◽  
Type I ◽  
Activity Based Costing ◽  
Cost Rate ◽  
Continuous Innovation ◽  
Magnetic Components ◽  
Alignment Process ◽  
Capacity Cost

The Electrical & Electronic (E&E) company is one of Malaysia’s leading industries that has 24.5% in manufacturing sector production. With a continuous innovation of E&E company, the current costing being used is hardly to access the complete activities with variations required for each workstation to measure the un-used capacity in term of resources and cost. The objective of this work is to develop a new costing structure using time-driven activity-based costing (TDABC) at . This data collection was obtained at E&E company located at Kuantan, Pahang that focusing on magnetic component. The historical data was considered in 2018. TDABC is used to measure the un-used capacity by constructing the time equation and capacity cost rate. This work found three conditions of un-used capacity. Type I is pessimistic situation whereby according to winding toroid core, the un-used capacity of time and cost are -14820 hours and -MYR2.60 respectively. It means the system must sacrifice the time and cost more than actual apportionment. Type II is most likely situation whereby according to assembly process, the un-used capacity of time and cost are 7400 hours and MYR201575.45 respectively. It means the system minimize the time and cost which close to fully utilize from the actual apportionment. Type III is optimistic situation whereby according to alignment process, the un-used capacity of time and cost are 4120 hours and MYR289217.15 respectively. It means the system used small amount of cost and time from the actual apportionment.

Implementation of Time-Driven Activity-Based Costing System in the Manufacturing Industry

2020 ◽  
pp. 272-283 ◽  
Author(s):  
Ahmet Özcan
Keyword(s):  
Manufacturing Industry ◽  
Business Environment ◽  
Activity Based Costing ◽  
Strategic Decisions ◽  
Quality Cost ◽  
Goods And Services ◽  
Costing System ◽  
The Cost ◽  
Capacity Cost

In the current business environment, the costing system used within the firms has prominent impact on strategic decisions. High-quality cost data significantly increases the quality of firms' strategic decisions. The activity-based costing system has failed to satisfy the needs of firms operating in the competitive economic environment. The time-driven activity-based costing system is the developed version of activity-based costing system. Time-driven activity-based costing system is one of the most sophisticated costing systems that enable firms to accurately calculate the cost of goods and services. Time-equations are used in time-driven activity-based costing system to estimate the time consumed by each activity. This chapter aims to discuss main dynamics of time-driven activity-based costing system and provides an illustration of this costing system in the manufacturing industry. The case study demonstrates that time-driven activity-based costing system is useful in calculating idle capacity cost.

An investigation into manufacturing performance achievements accrued by Indian manufacturing organization through strategic 5S practices

2018 ◽  
Vol 67 (4) ◽  
pp. 754-787 ◽  
Author(s):  
Jugraj Singh Randhawa ◽  
Inderpreet Singh Ahuja
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Manufacturing Sector ◽  
Successful Implementation ◽  
Automotive Manufacturing ◽  
Content Type ◽  
Manufacturing Performance ◽  
Improvement Programs ◽  
Manufacturing Organization

Purpose The purpose of this paper is to evaluate the quantitative and qualitative benefits accrued by an Indian automotive parts industry through strategic 5S implementation initiatives. Design/methodology/approach The study involves evaluation of steps involved in systematic implementation of 5S program methodology in an automotive manufacturing organization and investigation of achievements accrued by the industry through the successful implementation of 5S program. Findings The empirical results of the study have revealed that effective practice of 5S program brings considerable level of improvements in the quality, production, cost optimizations, employee’s morale values and work culture in the manufacturing industry. The industry accrued both tangible and non-tangible benefits through the holistic adoption of 5S principals. 5S principals have been envisioned to further support other quality improvement programs like lean manufacturing initiatives of the organizations. Research limitations/implications The limitation of the study is that this research has been carried out in only manufacturing industry while similar study will be conducted in the service industry also. Originality/value Global competition in the manufacturing sector has provided necessary impetus for manufacturing organizations for affecting continuous improvements in manufacturing performance for achieving sustainability and profitability in the competitive market. 5S implementation is the fundamental tool for the overall achievements in both quantitative and qualitative performance enhancements in the manufacturing as well as service organizations.

scholarly journals Constructing a new cost structure using time-driven activity-based costing for replanting at palm oil plantation

2021 ◽  
Vol 7 (1) ◽  
pp. 55-69
Author(s):  
Sri Nur Areena Mohd Zaini ◽  
Mohd Yazid Abu
Keyword(s):  
Palm Oil ◽  
Capacity Planning ◽  
Cost Structure ◽  
Activity Based Costing ◽  
Cost Rate ◽  
Practical Capacity ◽  
Systematic Development ◽  
Set Up ◽  
Unused Capacity ◽  
Capacity Cost

The palm oil industry in Malaysia is undeniably the pride of the country. However, in this plantation there are currently few issues which do not set up a time equation to interpret the variance of activities, the rate setting did not illustrate the correlation between the resources provided and the practical capacity, and the manager had no tool in place to monitor the unused capacity. In order to increase precision in the field of palm oil plantation, this work aims to develop a new cost structure. Time-driven activity-based costing (TDABC) has been introduced because it allows time output to be efficiently assessed, the idle capacity accurately defined, and the unused capacity separately to be recorded. This provides an overview of functional tools and their associated costs as well as measurement methods and facilitates quality improvement. This work focused only on replanting field and the plantation located in Pahang. The maximum replanting capacity cost rate (CCR), with 288600 minutes and 0.106 RM / minute, was subsequently successfully developed. Finally, the manager can observe that 68358.45 minutes of utilized capacity could be used for the systematic development of replanting capacity planning.

scholarly journals COMPARATIVE STUDY: ACTIVITY BASED COSTING AND TIME DRIVEN ACTIVITY BASED COSTING IN ELECTRONIC INDUSTRY

2020 ◽  
Vol 4 (1) ◽  
pp. 68-81
Author(s):  
N.F. Zamrud ◽  
M.Y. Abu
Keyword(s):  
Cost Allocation ◽  
Service Level ◽  
Activity Based Costing ◽  
Electronic Industry ◽  
Product Complexity ◽  
Cost Rate ◽  
Activity Cost ◽  
Economic Reality ◽  
Unused Capacity ◽  
Capacity Cost

By the 1980s, Traditional Cost Accounting (TCA) is no longer reflecting the current economic reality due to distorted information about the profitability of their orders, products, and customers. In addition, Activity-based Costing (ABC) is a costing method originally developed to overcome the shortcoming of TCA method in the era of rapidly increasing product complexity and diversification. However, it is not universally accepted because it ignores the potential for unused capacity which will be beneficial for forecasting. The objective of this work is to compare the advantages of ABC and Time-driven Activity-Based Costing (TDABC) by analyzing the features towards costing sustainment. The work begins by collecting data at electric electronic industry located at Pahang and the product selected is a magnetic inductor. ABC focuses on the costs inherent in the activity based products to produce, distribute or support the products concerned. TDABC uses time equation and capacity cost rate (CCR) to measure the unused capacity with respect to the time and cost. This work has successfully compares the methodology between ABC and TDABC in electronic industry. The item such as stages for cost allocation, determination of drivers, action taken for an additional activity, cost consideration for implementation, system building, system update, information given from each method, transparency, overestimation of cost, differentiation of service level, oversimplification of activities and capacity forecast and planning. It concludes that both have their strength according to the industry needs.

scholarly journals A Case Study on the Un-Used Capacity Assessment Using Time Driven Activity Based Costing for Magnetic Components

2021 ◽  
Vol 9 ◽  
pp. 32-53
Author(s):  
N.N.N.M. Kamil ◽  
S.N.A.M. Zaini ◽  
M.Y. Abu
Keyword(s):  
Historical Data ◽  
Manufacturing Sector ◽  
Type I ◽  
Activity Based Costing ◽  
Cost Rate ◽  
Continuous Innovation ◽  
Magnetic Components ◽  
Alignment Process ◽  
Capacity Cost

The Electrical & Electronic (E&E) company is one of Malaysia’s leading industries that has 24.5% in manufacturing sector production. With a continuous innovation of E&E company, the current costing being used is hardly to access the complete activities with variations required for each workstation to measure the un-used capacity in term of resources and cost. The objective of this work is to develop a new costing structure using time-driven activity-based costing (TDABC). This data collection was obtained at E&E company located at Kuantan, Pahang that focusing on magnetic component. The historical data was considered in 2018. TDABC is used to measure the un-used capacity by constructing the time equation and capacity cost rate. This work found three conditions of un-used capacity. Type I is pessimistic situation whereby according to winding toroid core, the un-used capacity of time and cost are -14820 hours and -MYR2.60 respectively. It means the system must sacrifice the time and cost more than actual apportionment. Type II is most likely situation whereby according to assembly process, the un-used capacity of time and cost are 7400 hours and MYR201575.45 respectively. It means the system minimize the time and cost which close to fully utilize from the actual apportionment. Type III is optimistic situation whereby according to alignment process, the un-used capacity of time and cost are 4120 hours and MYR289217.15 respectively. It means the system used small amount of cost and time from the actual apportionment.

scholarly journals Application of the TDABC model in the logistics process using different capacity cost rates

2016 ◽  
Vol 9 (5) ◽  
pp. 1003 ◽  
Author(s):  
Paulo Afonso ◽  
Alex Santana
Keyword(s):  
Cost Model ◽  
Deep Understanding ◽  
Activity Based Costing ◽  
Cost Rate ◽  
Study Results ◽  
Unused Capacity ◽  
Logistics Process ◽  
The Cost ◽  
Capacity Cost

Purpose: The understanding of logistics process in terms of costs and profitability is a complex task and there is a need of more research and applied work on these issues. In this research project, the concepts underlying Time-Driven Activity Based Costing (TDABC) have been used in the context of logistics costs.Design/methodology/approach: A Distribution Centre of wood and carpentry related materials has been studied. A multidisciplinary team has been composed to support the project including the researchers and three employees of the company responsible for accounting, logistics and warehousing. The design and implementation of the costing model asked for a deep understanding of the different tasks and processes that should be considered. Accordingly, a TDABC model for the logistics function was developed.Findings: The cost model presented here is supported on a series of time equations designed for the logistics function which allow the analysis and discussion of costs and profitability of different cost objects namely, products, clients, distribution channels, processes and activities. The cost of unused capacity and the effectiveness of logistics processes are also highlighted in this model.Research limitations/implications: In a case study, results and implications cannot be directly or immediately generalized. Nevertheless, the proposed time equations and cost model can be easily adapted to explain other types of logistics functions and it gives the foundations or other TDABC models with more than one capacity cost rate.Practical implications: The TDABC model developed in this case study can be used in similar cases and as a basis for the analysis of logistics costs in other logistics processes. Furthermore, managers can rely on the proposed approach to analyze products’ profitability and logistics cost structure. Originality/value: In this case, different capacity cost rates were computed in order to reflect appropriately the logistics function which was presented in two different processes: internal logistics and distribution. These processes have specific resources allocated and should be measured differently. This is in line with Kaplan and Anderson (2004, 2007) who have suggested a more complex TDABC model with more than one capacity cost rate for these situations.

Lean Production Weaknesses in Manufacturing Industry: A Review

2015 ◽  
Vol 735 ◽  
pp. 344-348 ◽  
Author(s):  
K.K Nithia ◽  
Mohd Yusof Noordin ◽  
Muhamad Zameri Mat Saman
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Review Paper ◽  
Lean Production ◽  
Agile Manufacturing ◽  
Review Literature ◽  
Shop Floor ◽  
Automotive Manufacturing ◽  
Manufacturing Sectors

This is a review paper written to discuss the lean manufacturing and the lean weaknesses in manufacturing industry. Lean production or also known as lean manufacturing has been widely practiced as a production improvement tool in manufacturing sectors. Lean manufacturing originated from Japanese automotive manufacturing sectors for about five decades. Over the decades, lean production system have evolved from shop floor improvement tool to a philosophy. The problem statement in this research was to review the weaknesses of lean production system. The purpose of this review paper is to discuss the weaknesses of the lean production system and overview the available methods to address the weaknesses. Limitation and scope of this paper were within manufacturing industry and period of literature reviews. The methodology applied was review literature from the lean manufacturing related journals dated from year 2000 to 2014. Then by consolidating the lean production weaknesses data in to categories of people, material, equipment, know-how, business and planning or scheduling. The authors discussed to elaborate further on the lean weaknesses and methods of addressing it. Therefore, understanding the weaknesses will allow the academic and industry to co-create new solution methods for an effective lean production system. In conclusion, the authors view the weaknesses as an opportunity to integrate with other theories such as agile manufacturing, sustainable development, human factor, safety management and cleaner production in the future.

scholarly journals case study on the determination of unused capacity using time driven activity-based costing for electronic component

2020 ◽  
Vol 7 (2) ◽  
pp. 74-85
Author(s):  
N.F. Zamrud ◽  
S.N.A.M Zaini ◽  
M.Y. Abu
Keyword(s):  
Time Allocation ◽  
Cost Estimation ◽  
Group Identification ◽  
Capacity Utilization ◽  
Electronic Component ◽  
Activity Based Costing ◽  
Cost Rate ◽  
Practical Capacity ◽  
Unused Capacity ◽  
Capacity Cost

Nowadays, demand for magnetic components are increasing from customer to support technological needs. It is important for the producer to incorporate an accurate cost estimation to decide the best price to gain better profits. However, actual costing structure is ignored the potential of time equation and capacity cost rate to measure the unused capacity from the resources allotment. The objective of this work is to determine the unused capacity in term of duration and cost in the manufacturing of electronic component using time-driven activity-based costing (TDABC). The method was developed using seven stages which are resources group identification, estimate cost of resources supplied, practical capacity estimation, capacity cost rates calculation, time equation development, determine time estimates for each sub-activity and estimate capacity cost required. As a result, in sub-activity-1, the unused time was 246,156.29 minutes which needs to be re-examined so that maximum time for productivity can be achieved and the unused capacity of cost was MYR 623,804.93 which conveys the message of wastage at the workstation. In sub-activity-3, the amount of unused time and cost was -596,400 minutes and MYR -7,006,252.43 respectively. The negative value demonstrated that the operators are overworked than normal time allocation. In sub-activity 9, the amount of unused time was -596,400 minutes and MYR -7,006,252.43 for unused cost probably the job scopes were taking more time than it should to be completed. Therefore, by applying the TDABC method, the capacity utilization and time efficiency can be clearly viewed.

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