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1,2005
EXECUTIVE SUMMARY The target costing method works "backward" from traditional cost-plus methods and begins with a targeted sales price for a product. This price is set based on what the customer is willing to pay. It considers not only the preferred current selling price but also the later life cycle pattern of prices. This technique has key managerial implications. This article considers these implications along with implementation guidelines. Examples of industries successfully using target costing are included. Ongoing controversies concerning where the techniques can best be used are discussed. Further considered are international differences in target costing as well as challenges of global outsourcing along the supply chain. The article ends with implementation challenges, significance for practice, and suggestions for future research.
activity based cost management approach throughout the global supply chain. Target costing reduces costs by involving suppliers and manufacturers as contributors to the design process, thereby focusing the entire chain toward the overarching goal of eliminating costly waste, excess, and unevenness. The supply chain partners can also consider costs of reclamation and disposal of products after their useful life in a total, closed-loop life cycle costing model.
TARGET COSTING Most American and European firms have long used the traditional techniques of standard costing. In price-based target costing, a company sets a target cost through comparison of competitive products. They gather data on the market price and subtract their desired profit margin. This desired profit margin will almost always greater than the cost of capital but is infiuenced by macro environmental forces as well as shareholder goals. When the product being developed does not meet the target cost and profit, often it is not commercialized. While it may be important as a tool to those competing on delivery speed, quality, product fiexibility, or delivery reliability, the target costing technique is more useful to those manufacturers who mass produce a make-to-stock item in a competitive market in which customers are most sensitive to price and cost levels. Originating in Japan, target costing is used in over 80 percent of Japanese assembly companies (Kroli, 1997) and by 100 percent of Japanese car manufacturers (Boer and Ettiie, 1999). Komatsu, Olympus, Sony, Topcon, and Isuzu are also key users (Cooper and Slagmulder, 1997). Yet outside Japan, target costing receives very little publicity and is only used by 40 percent of US firms (Pierce, 2002). Selecting and Involving Suppliers Target costing is not just a cost reduction technique or control framework, but part of a comprehensive strategic profit management system including value analysis and value engineering. Implementing target costing within the supply chain required substantially more effort and discipline than using standard costing. All supply chain partners must find ways to reduce costs as they design, manufacture, and distribute components (Cooper and Slagmulder, 1999b). Once the selling price has been set, the manufacturer and entire supply chain must deduct their profit margins and determine the costs of the end product. Target costs for all components will
INTRODUCTION Mergers, acquisitions, and consolidations continue to change the scope and size of many firms. While larger companies benefit from economics of scale and larger research and development departments, leading to lower production prices, the consolidation and increased merger activity brings disadvantages as well. The key disadvantage is competition from both domestic and global players with differing production and delivery costs. The dilemma for manufacturers is to match the lower prices of the global competition and still offer the highest quality products customers demand. Target costing may serve as a solution when developing new products, minimizing costs through the optimal use of all resources along the entire supply chain (Ahmed, Berry, Cullen, and Dunlop, 1997; Zsidisin and Ellram, 2001; Lockamy and Smith, 2000; Welfle and Keityka, 2000; and Shank and Fisher, 1999). Lockamy and Smith (2000) agree target costing focuses less on cost and considers customer requirements to be the primary cost driver. Cost is seen as a result of the process whether focusing on a price-based approach, a value-based approach or an
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EXAMPLES IN PRACTICE AND INDUSTRY SUCCESSES In the past, researcher's lists of successful companies and industries adopting target costing included Toyota, Nissan, Sony, Matsushia, Daihatsu, Canon, Olympus Optical, and Komatsu and later added non-Japanese companies including Mercedes, Goodyear, Rockwell, Texas Instrument, DaimlerChrysier, and the North Sea oil industry (see for example Cooper and Slagmulder, 1997; Knott, 1996; and Tanaka, 1993). Nicolini, Tomkins, Holti, Oldman, and Smalley (2000) added the UK construction sector while Ellram (2000) included the semiconductor, automotive, and electronic equipment industry as well as the computer peripheral, consumer products, and aerospace original equipment manufacturers as participating in the target costing processes. Ellram (2000) found organizations had multiple objectives for implementing target costing including reducing costs, understanding the supplier's cost structures, improving internal cost management.
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BARRIERS Target costing has a number of implementation challenges. Banham (2000) quotes the Senior Manager of Finance at Boeing and agrees implementation barriers include: lack of understanding in corporate America (in fact the term is not well known and much of the Japanese literature on "drifting cost" has not been translated); cultural barriers against cross-functional cooperation; organizational barriers to team oriented work (difficult to achieve in a functional structure); and a perceived irrelevance about the effects. Still other barriers may include the organizations information systems and its lack of total system integration. To share cost reductions, supply chain partners must be able to share initial cost and production data. Lack of Understanding or Relevance Nicolini, Tomkins, Holti, Oldman, and Smalley (2000) agree the target costing concept as Japanese in origin. The Japanese name for the process Genka Kikaku expresses an overall strategic approach to cost reduction. Even the continuous improvement or "kaizen costing" is very much a Japanese approach that has found common usage in quality literature yet the approach to costing is not a mainstream business term. The shortening life cycles make the development, planning, and other phases of a product critical to understanding its costs (Choe, 2002). While target costing has a straight forward logic, the implications in practice are more difficult, particularly when the culture has previously embraced a cost-plus approach to pricing. The costplus approach is often quicker and does not involve an iterative, inclusive approach to reducing the gap between current costs and target cost as in target
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costing. The cost-plus approach also does not have a strong market orientation that is a prerequisite for target costing. The term too is seen as limited to the accounting domain and traditionally accountants have not been used to implement production changes, even though they have access to the cost data. In addition to costs, firms must understand what consumers really want and are willing to pay for. In the traditional approach to product development and cost-plus pricing, the result is an array of over engineered products that do not meet the customer's needs and are incorrectly priced. Burscher and Laker (2000) call this flawed process an "inside-out" approach and argue the cost of the product can not be established until the final product is ready to be launched. In addition to greater understanding of target costing, the authors urge for implementation in the initial stages of product development where modifications can be made cheaper and easier. Team and Cross-Functional Barriers The logic of target costing is easy to understand, yet a number of industries continue to use the prevailing cost-plus approach. This may be due in part to lack of understanding of costs throughout the supply chain and not having tightly linked, communicating supply chain partners. Workers will learn faster and better understand costs and the organization as a whole will adopt target costing as information flows faster and with a greater frequency of reporting. Zsidisin, Ellram, and Ogden (2003) agree the ability for all individuals to fully participate in cost management activities can lead to the development of valuable knowledge. They urge, however, the process takes an extensive degree of time and commitment. Target costing, implemented correctly, will engage all the key functions in the organization. They further assert the cross-functional teams formed between purchasing and supplier organizations can help reduce supply chain costs. When using target costing within the supply chain, the importance of trust and cooperation is crucial. Transferring previous in-house functions to partners or outsourcing can be a risk due to the inability to monitor or control the output of the desired function. When functions are performed at the manufacturer's plant, expectations and standards are communicated and understood, but these communications are often lost when the function is transferred to one of the partners in the chain. One way to control this problem is by the placement of one of the manufacturer's employees within the supplier's plant to monitor and aid the activities ofthe supplier.
Even the US Air Force can benefit by the use of target costing in their procurement process which would enable smaller suppliers to participate effectively as subcontractors. The article stresses the use of target costing as a way to build the long-term relationships necessary for small supplier development, and developing small suppliers is a legislative mandate of the U.S. federal govemment ("Paper Chase," 2003). Irrelevance or Fear ofthe Effects To many managers, target costing sounds like another buzz word or accounting term with little relevance to manufacturing or marketing. Yet, the concept of target costing is identical to the lean concepts implemented in manufacturing to reduce non-value added, irrelevant activities that do not contribute to a product's value. These terms, in practice, are attempting to reach a similar end. Quality, sole sourcing, and reducing wastes are part of a life cycle of continuous improvement of which target costing is an important component. Tinkler and Dube' (2002) support the use of target costing, activity-based planning, value chain analysis, and internal business processes combined in one system or integrated management framework. They agree these techniques provide weapons to be successflil but also provide the guidance systems to maneuver in the complex world of business. Target costing also has costing and profit implications internally as firms set transfer prices among divisions (Chen and Chung, 2002). On the fear side, cost setting negotiations must take place and often one or more groups feel they are shouldering too much of the cost reduction pressure, particularly smaller partners with less power within the chain. Design changes and cost cutting measures may even cause employees to fear for their jobs and work against the target costing process. This is overcome through training and ongoing education about the process and its importance and working to ensure job security as possible. Production Detail In target costing, the design process must be broken down into its lowest level components. For example an automobile manufacturer must chart the entire production process and go through a product's complete, lowest-level, bill of materials to uncover areas for improvement - connections that can be made with two screws instead of four, parts that would meet engineering specifications with one weld instead of three, parts that could be installed without painting them first - and many other ways to save a processing step. This detail requires the hands-on involvement of manufacturing, design engineering.
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IMPLICATIONS FOR MANAGEMENT Today supply chain partners are selected before product development, regardless of whether target costing is used. When choosing a supply chain partner, the costs of the supplier are rarely the deciding factor. Relevant factors are reliability, cooperation, ability to produce quality parts, the number of engineers and design experts employed, and reputation within the industry for service and dependability. It is very important for these factors to be carefully examined by the manufacturer because the suppliers will be included in every decision throughout the development of the new product and beyond. To aid in selecting the right supplier, manufacturers ofren institute a qualifying or certification program. Suppliers, who qualify, can be assured a long-term contract with the manufacturer. Carefully choosing the right supply chain partner makes the difference in whether the target cost is reached or not. A bad choice can be disastrous and conversely a good partner can be a tremendous asset. Some of the benefits of properly implementing target costing within the supply chain include selecting the most appropriate product development and process technologies, minimizing the complexities of product-lines, eliminating cost overruns, limiting design problems and delivering the lowest priced, highest valued product to the final customer (Laseter, 1998). Other trends include value engineering, parts standardization, and a sharing of knowledge along the supply chain. Chrysler's SCORE program (Supplier Cost Reduction Effort) is an example of a firm working closely with suppliers for cost savings. Suppliers benefit from long-term contracts and have a reduced risk of emergency demands for price reductions (Pierce, 2002). Research at the University of Birmingham (UK) found the use of target cost contracts is increasing and studies found share profiles vary with the amount of production (Broome and Perry, 2002). If the design team has difficulty meeting a target cost, a systematic approach can be taken. First, it may be important to review the target cost to determine if the cost can be raised or if margins can be reduced. The next step is to review the manufacturing process for a possible modification or relaxation of product functionality requirements. It may be useful to make improvements in the machinery tooling to meet target costs. Another avenue is to reduce supplier costs.
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DISCUSSION AND AREAS FOR FUTURE RESEARCH Although target costing is more time intensive than the traditional methods of cost-based pricing; manufacturers can be assured prices will be in line with customer expectations. As the examples in practice illustrate, time is also needed to bring all costs throughout the supply chain to acceptable levels. From a strategic perspective on new product development and implementation, costs must be developed quickly and products introduced before customer's tastes and needs change. Costing must also occur early in the developmental stages of a product while designs are easy and less costly to change. Intemally, coordination and involvement of financial and accounting professionals is needed to implement target costing as is close monitoring of marketing and quality control throughout the entire process in order to be a success. Areas for future research include extensive reviews of companies implementing target costing. Organizing this literature into theory-building can help practitioners identify the process order and other implementation challenges as well as ways to overcome them. In the academic arena, the topic needs broader coverage in textbooks, particularly and simultaneously in cost accounting, production and operations management, design and project management, and supply chain management. Cases for discussion warrant inclusion in these textbooks and other ancillary educational material to better train the next generation of managers in target costing. Even a target costing game or role playing exercise among supply chain members could be developed to illustrate the process.
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Porter,
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Marilyn M. Helms is Sesquicentennial Endowed Chair and Professor of Management at Dalton State College in Dalton, GA. Lawrence P. Ettkin is Marvin E. White Professor and Head of Management and Marketing at University of Tennessee at Chattanooga in Chattanooga, TN. Joe T. Baxter is Associate Professor of Management Information Systems at Dalton State College in Dalton, GA. Matthew W. Gordon is an Accountant at Eaton Cutler-Hammer in Cleveland, TN.
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