Mulhall, Inc., has a JIT system in place. Each manufacturing cell is dedicated to the production of a single product or major subassembly. One cell, dedicated to the production of mopeds, has four operations: machining, finishing, assembly, and qualifying (testing). The machining process is automated, using computers. In this process, the model’s frame and engine are constructed. In finishing, the frame is sandblasted, buffed, and painted. In assembly, the frame and engine are assembled. Finally, each model is tested to ensure operational capability. For the coming year, the moped cell has the following budgeted costs and cell time (both at theoretical capacity):
Budgeted conversion costs......... $ 6,696,000
Budgeted materials............ $18,600,000
Cell time................. 37,200
Theoretical output............. 27,900 models
During the year, the following actual results were obtained:
Actual conversion costs.......... $6,696,000
Actual materials............. $4,030,000
Actual cell time............. ... 37,200 hours
Actual output.............. 23,250 models
Required:
1. Compute the velocity (number of models per hour) that the cell can theoretically achieve.
Now, compute the theoretical cycle time (number of hours or minutes per model) that it takes to produce one model.
2. Compute the actual velocity and the actual cycle time.
3. Compute MCE. Comment on the efficiency of the operation.
4. Compute the budgeted conversion cost per minute. Using this rate, compute the conversion cost per model if theoretical output is achieved. Using this measure, compute the conversion cost per model for actual output. Does this product costing approach provide an incentive for the cell manager to reduce cycle time? Explain.