Soft Spot is a manufacturer of futon mattresses. Soft Spot’s mattresses are priced at $60, but

$22.00

Description

Soft Spot is a manufacturer of futon mattresses. Soft Spot’s mattresses are priced at $60, but
competition forces the company to offer significant discounts and rebates. As a result, the
average price of the futon mattress has dropped to around $50, and the company is losing money.
Management is applying value chain analysis to the company’s operations in an effort to reduce
costs and improve product quality. A study by the company’s management accountant has determined the following per unit costs for primary processes and support services:
Primary Process
Cost per Unit
Research and development
$ 5.00
Design
3.00
Supply
4.00
Production
16.00
Marketing
6.00
Distribution
7.00
Customer service
1.00
Total cost per unit
$42.00
Support Service Human resources $ 2.00
Information services
5.00
Management accounting
1.00
Total cost per unit
$ 8.00
To generate a gross margin large enough for the company to cover its over-head costs and earn a
profit, Soft Spot must lower its total cost per unit for primary processes to no more than $32.00
and its support services to no more than $5.00. After analyzing operations, management reached
the following con-clusions about primary processes and support services:
• Research and development and design are critical functions because the market and
competition require constant development of new features with “cool” designs at lower cost.
Nevertheless, management feels that the cost per unit of these processes must be reduced by 20
percent.
• Ten different suppliers currently provide the components for the futons. Ordering these
components from just two suppliers and negotiatin glower prices could result in a savings of 15
percent.
• The futons are currently manufactured in Mali. By shifting production to China, the unit cost of
production can be lowered by 40 percent.
• Management believes that by selling to large retailers like Wal-Mart it is feasible to lower
current marketing costs by 25 percent.
• Distribution costs are already very low, but management will set a target of reducing the cost
per unit by 10 percent.
• Customer service and support to large customers are key to keeping their business.
Management therefore proposes increasing the cost per unit of customer service by 20 percent.
• By outsourcing its support services, management projects a 20 percent drop in these costs.
Required
1. Prepare a table showing the current cost per unit of primary processes and support services
and the projected cost per unit based on management’s proposals.

2. Will management’s proposals achieve the targeted total cost per unit? What further steps
should management take to reduce costs?
3. What role should the company’s support services play in the value chain analysis?
Financial Performance Measures
C 2. Tarbox Manufacturing Company makes sheet metal products for heatingand air
conditioning installations. Its statements of cost of goods manufacturedand income statements
for the last two years are presented below and on the next page.
Tarbox Manufacturing Company
Statements of Cost of Goods Manufactured
For the Years Ended December 31
This Year
Last Year
Direct materials used Materials inventory, beginning
$91,240
$93,560
Direct materials purchased (net)
987,640
959,940
Cost of direct materials available for use
$1,078,880
$1,053,500
Less materials inventory, ending
91,240
Cost of direct materials used
$962,260
Direct labor
Overhead
Indirect labor
Power
Insurance
Supervision
Depreciation
Other overhead costs

95,020
$983,860
571,410
$182,660
34,990
22,430
125,330
75,730
41,740

$171,980
32,550
18,530
120,050
72,720
36,280

Total overhead
452,110
Total manufacturing costs
$1,994,090
Add work in process inventory, beginning
152,275
Total cost of work in process during the period
$2,146,365
Less work in process inventory, ending
148,875
Cost of goods manufactured
$1,997,490

579,720

482,880
$2,038,150
148,875
$2,187,025
146,750
$2,040,275

Sales
Cost of goods sold Finished
Goods inventory, beginning

$2,942,960
$142,640

Cost of goods manufactured
2,040,275
Cost of goods available for sale
$2,182,915
Less finished goods inventory, ending
186,630
Total cost of goods sold
1,996,285
2,039,670
Gross margin
$946,675
Selling and administrative expenses
Sales salaries and
Commission expense
$394,840
Advertising expense
116,110
Other selling expenses
82,680
72,930 Administrative expenses
242,600
195,530
Total selling and administrative expenses
836,230
792,230 Income from operations
$110,445
$264,320
Other revenues and expenses Interest expense
54,160
56,815 Income before income taxes
$207,505 Income taxes expense
87,586
Net income
$37,148
$119,919

$3,096,220
$184,820
1,997,490
$2,182,310
142,640
$1,056,550
$329,480
194,290

$56,285
19,137

For the past several years, the company’s income has been declining. You have been asked to
comment on why the ratios for Tarbox’s profitability have deteriorated.
1. In preparing your comments, compute the following ratios for each year:
a. Ratios of cost of direct materials used to total manufacturing costs, direct labor to total
manufacturing costs, and total overhead to total manufacturing costs. (Round to one decimal
place.)
b. Ratios of sales salaries and commission expense, advertising expense, other selling
expenses, administrative expenses, and total selling and administrative expenses to sales. (Round
to one decimal place.)
c. Ratios of gross margin to sales and net income to sales. (Round to one decimal place.)
2. From your evaluation of the ratios computed in 1, state the probable causes of the decline in
net income.
3. What other factors or ratios do you believe should be considered in determining the cause of
the company’s decreased income?

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