Product Valuation Inventory
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Former CFO, Marshfield Door Systems 2 1 Creating a Lean Centric System A NEED FOR CHANGE 9/6/2011 JeanCunninghamConsulting.com 3 Traditional Plant 1 Plant 2 Sales 1303 1303 COGS 900 900 Variances 12 ( 125) GM 391 Productivity/employee 200 9/6/2011 JeanCunninghamConsulting.com 30 528 41 250 4 2 Lean Plant 1 Sales Plant 2 1303 100 1303 100 Material 517 40 517 40 Supplies 72 5 72 5 Net freight 54 4 54 4 Variable margin 660 51 660 51 Labor and benefits 190 15 190 15 Fixed cost (leases, dpr, utilities) 42 3 42 3 Cost (to)/from inventory 37 3 ( 100) (8 ) Total cost of sales 912 70 775 59 GM 391 30 528 41 Natural margin 428 33 428 33 Shipments/employee 225 9/6/2011 225 JeanCunninghamConsulting.com 5 Information Alignment 9/6/2011 JeanCunninghamConsulting.com 6 3 Evaluate and/or Eliminate Standard Cost Accounting Sam and his saw 9/6/2011 JeanCunninghamConsulting.com 7 “Standard Cost Isn’t Working” Flags • Large variances • Budgeting for variances • Mix is your main “reason” • Ending products that have positive variable margin without replacement products • Analysis of in‐source or out‐ source uses standard t d d costt 9/6/2011 • Lack of decisions from standard cost • Data collection effort is greater than “decision” actions • Lack of articulated reasons for standard cost • Deciding what products to manufacture based on standard hours JeanCunninghamConsulting.com 8 4 Examples 9/6/2011 JeanCunninghamConsulting.com Export Domestic Total Company 25,300 18,500 6,800 Export Cost Domestic Cost Allocation 12,000 7,500 4,200 300 Sales Before Cost of Goods Sold Gross Profit 13,300 Expenses Operating Overhead Financial TOTAL PROFIT 9/6/2011 9 JeanCunninghamConsulting.com 4,200 3,400 800 4,900 10 5 After New Orders Domestic Export Total Sales Material Content Domestic Export Freight Variable Margin Variable Margin Phase 1 Mfg Phase 2 Mfg Shared Management Engineering Maintenance Absorption Gross Margin Sales Accounting IT TOTAL PROFIT 9/6/2011 Total Company Product Family 1 Pro
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