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3-32 Complexity of Operations and the Effect on Cost (15 min)
The observations made by the consultant show that the manufacturer was
incurring large costs in operations, distribution, and administration due to
the high level of complexity in its products. Maintaining relationships with
10 vendors for a single item contributed to high purchasing and stocking
costs. Similarly, most of the firm’s volume was made up of products with
five color combinations, with the result that manufacturing, warehousing,
shipping and selling costs were high relative to fewer color combinations.
Also, the high product variety required smaller batch production and more
demands for smaller batch sizes without increasing overall costs. The
result of the program was that overall profit margins improved. The firm
had found a way to deal with the cost consequences of its strategic
initiative.
Also, the firm adopted new cost management practices that included
new non-financial measures such as set-up time and frequency, percent of
orders shipped on time, percent of orders on just-in-time, and number of
vendors for the top 20 commodity raw materials items. In addition, the firm