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Directly charged to
Direct material
Production Product
department contract
Direct labour 1, 2, 3 1, 2, 3
*Note: In Xu Ji, direct labour cost – instead of being charged directly to products – was allocated first to production departments then to finished products.
This practice was common in some Chinese manufacturing companies as it was relatively difficulty to track direct labour to individual products without using
sophisticated tools such as Manufacturing Resource Planning (MRP) systems or some elaborate recording mechanism within a mass production.
1 In 2001, Xu Ji’s main production departments comprised of the first production department (FPD) and second production department (SPD). FPD
manufactures Xu Ji’s high yield products such as high-voltage electric equipment. SPD manufactures relatively low yield products such as safety and
automation systems.
ABC system at the Relay subsidiary With the lessons learnt from the ABC implementation, Xu Ji’s
ABC team, together with Relay accountants and the software
Xu Ji Relay company manufactures many different relay
company – which developed FPD’s ABC system – embarked
products and sells internally to other Xu Ji subsidiaries as well as
on developing its own ABC system at Relay in late 2004. The
outsiders. The organisational structure is independent to the rest
cost structure in Relay comprised 85% direct materials and
of the group and has full financial autonomy. Relay operates in
15% direct labour, variable and fixed overheads. During the
a highly competitive and saturated market, so its main aim has
implementation, the team realised the main inaccuracy of
been to survive and avoid closure. An urgent need was to get
Contract costs
Technical support Chief engineer office Proportion of product revenue of assemble lines
Chief engineers
planning office
Finance office
Warehouse
Production
After-sales
Marketing
Technical
support
office
Assemble lines
Intermediate transform
Wiring assemble
Transform Relay
Relay assemble
WGB assemble
Direct Relay
Transformer
Timer Relay
Packaging
assemble
Directly traced to
Product costs
Customers Suppliers
Notes:
1. The sales companies of XJG is an independent business unit, which deals with all sales orders for the group. The sales companies charges Xu Ji for relevant
expenses except the salary costs of its sales staff.
2. Yi Wan Logistic is one of the subsidiaries of the group and the sole authorised purchasing company for the group. The company purchases all raw materials
and components which are not manufactured internally. Yi Wan Logistics charges a commission of 0.1% for all purchases.
3. The main functions of the production planning division are to set production plans based on customers’ specifications and place production orders to both
production departments and component assembly divisions.
Source: Liu and Pan (2007)
Front-stage – marketing activities to enter new Facility-level Average or other subject measures – e.g.
markets and/or general profile-raising activities geographic sales percentage
Marketing materials
Mid-stage – contracts-related
Salaries of sales staff Sustaining-level Geographic area – first trace to geographic areas
then allocated to contracts value in geographic
area
* This only includes salaries of sales staff members assisting the marketing activities. It does not include those of chief executives and general managers of sales
companies.
2 Ironically, at the initial ERP briefing meeting in 2010, the ERP programmers did not think the ERP system could either create a data-exchange link to the
existing ABC system or incorporate the ABC concepts within the ERP programme. However, this view has changed to incorporate the ABC concepts in ERP’s
management reporting system.
1970 – 2001 2001-Jun 2003 Jul 2003- May Jun 2004-Nov Dec 2005- Jan 2008 – Mar 2011
2004 2005 Dec 2007
Part 1:
ABC Archive Active design Design Ongoing ABC Initiation Verification of ABC
implementation research and build ABC standard ABC system updates of rolling models and activities
at the first model, redesign system; out ABC to be in line with changed
production work processes company organisational structure
division wide
Research activities ABC concept ABC system Interviews and Interviews Retrospective study with
training and training, focus groups in opinions gathering
field study interviews and November 2005
focus groups
in August
2003
Participants Accounting ABC team and ABC team and ABC team, Semi-structured interviews
involved and operations operations operations group with top and front line
personnel managers managers accountants managers; accounting staff;
and top- and and ABC team
middle-line
managers
Part 2:
Part 3:
Major corporate
events