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Product Costing Systems
Product Costing Systems
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any firms use cost of improving the
product cost- Many product costing methods and systems exist, cost system becomes
ing information but having the right costing system for a given a strategic investment
to value inventory for situation can be difficult. This article identifies four rather than an unfavor-
financial reporting pur- key questions to answer and points out the advan- able spending vari-
poses. However, having tages and disadvantages of various cost systems ance. While managers
timely, relevant cost to find the right balance of convenience, correct- realize the problems
information is essen- ness, and implementation costs in a product cost- caused by relying on
tial for profitability flawed cost informa-
ing system. Nestlé, for example, discovered that
analysis and strategic tion, it is challenging
planning. Consider good product management, aided by better cost to identify the appro-
the following story. A systems, can pay major dividends. priate cost system.
few years ago, after © 2012 Wiley Periodicals, Inc. Complicating the task
implementing a more is the fact that different
detailed costing system, strategic decisions call
Nestlé SA Chief Executive Peter for different product costs. The
Brabeck made an unexpected Resource Planning (ERP) sys- purpose of this article is to help
and alarming discovery: His tem led Nestlé to jettison weaker companies determine the right
company was producing 130,000 brands, consolidate product offer- product cost system approach.
variations of its various brands, ings, and make significant adjust- First, we discuss why choosing
and 30 percent weren’t making ments in strategic direction. As the right costing approach is
money.1 Excessive focus on vari- Nestlé discovered, selecting the important. Second, we discuss
able costs and spare capacity correct product costing system for four key questions that must be
led to the conclusion that many strategic decisions can be chal- answered when selecting a cost-
new products were “profitable” lenging but is essential in guiding ing approach and the associated
and long-term winners. Nestlé’s firm strategy. The wrong system options. Lastly, we describe
margins were lower than com- can lead to faulty strategic deci- actions to take to achieve a
petitors, however, which strongly sions with disastrous results. proper fit.
suggested that these seemingly We have found that many
“profitable” products were actu- firms underinvest in their prod- Why Product Cost Systems
ally decreasing firm profit. Care- uct costing systems. But if Matter
ful consideration of the cost and improvements in product cost
profitability analysis provided by accuracy would lead to differ- So why do companies
its new sophisticated Enterprise ent decision outcomes, then the need a costing system? First,
generally accepted accounting desire more accurate product and maintaining the current
principles (GAAP) and Inter- costing systems but have trouble system reasonable?
national Accounting Standards justifying the cost. We have also
(IAS) require the determination found, however, the cost infor- There are some “red flags”
of the cost of goods sold or ser- mation philosophy to be quite to look for when assessing your
vices performed for financial different in Europe. One Ger- system. Do competitors’ prices
reporting. Financial accounting, man controller of a company appear to be unrealistically
however, does not require a high with a very detailed costing low? Does it take weeks to do
level of accuracy or relevance system expressed a commonly a special cost study to get the
for product costing—the method held view when he said, “How information needed for a stra-
simply needs to be systematic can you not have this level of tegic decision? Do marketing
and reasonable. Second, prof- detail?” The benefits of a supe- managers want to continue prod-
itability assessment is a key rior costing system are real but ucts that show high profits in the
component of strategic analysis. hard to quantify in return on accounting reports but are com-
Many important strategic deci- investment (ROI) calculations, plex to produce? Do operational
sions are made at the product- and implementation costs can managers use their own cost
line level. For almost any firm seem onerous. In general, it is systems for product decisions?
producing a large and diverse set difficult to quantify all benefits If the current system shows any
of products in different facili- prior to system implementation. of these warning signs, or falls
ties and countries (e.g., Nestlé), Improving a cost system should short on one or more of the
product profitability helps dimensions, then a new
guide product portfolio cost system may be appro-
decisions. Third, product Quite simply, the single best product priate. When selecting a
costing systems can help new product cost approach,
in cost and operational cost system for all possible purposes there are four key questions
control. does not exist. Selecting a costing that must be addressed.
Unfortunately, given Answering these questions
diverse demands on cost system and philosophy requires a will guide the selection
information, there is no careful consideration of costs and process.
single system that meets
every reporting and stra-
benefits.
Four Key Questions in
tegic need. Additionally, Product Cost Design
different operational set-
tings call for different Unfortunately, the myriad
costing approaches. A system be approached as a strategic approaches to product costing
that is appropriate for a Nestlé investment. and choices available can inhibit
Purina pet food factory making a systematic design approach. In
a few flavors of dog food would Assessing Your Current selecting a product cost system,
not be appropriate for a Nestlé System a firm needs to answer four key
confectionery plant making doz- questions:
ens of different candies. While So how do you know if you
this fact may be unsettling for have a satisfactory system? We 1. Which costs should be
managers who desire certainty, it recommend assessing your cur- included in product cost?
also relieves the pressure to find rent system against three dimen- 2. At what level of detail
the one and only cost number or sions: should we track direct
system. Quite simply, the single product costs?
best product cost system for • Convenience: how conve- 3. How do we organize indirect
all possible purposes does not nient is it to get the cost product costs?
exist. Selecting a costing system information needed? 4. How do we allocate indirect
and philosophy requires a care- • Correctness: are the current costs to products?
ful consideration of costs and product costs reasonably
benefits. accurate? Addressing these questions
In our experience, we have • Costs of implementation: are will help guide system selec-
found that most companies the costs of implementing tion. Understanding the various
commonly used in just-in-time It is important to emphasize trum tracks costs by job (or
production environments. On that one product cost definition product). Job costing is most
the other hand, this methodol- cannot meet all costing needs. appropriate when each job or
ogy does not measure full costs For example, for inventory con- product is unique, but it can lead
and would be inappropriate for trol purposes, a firm may select to unnecessary recordkeeping for
making many strategic decisions throughput costing, while for costs that are common to all jobs.
(e.g., cost-based pricing). pricing decisions the firm may At the other end of the spec-
Variable costing includes all use a more inclusive definition. trum is resource consumption
variable manufacturing costs. Exhibit 3 provides a list of typi- accounting (RCA), where costs
This methodology is more cal product cost definitions along are tracked at the individual
appropriate when variable costs with associated pros and cons. resource cost center level for
are significant and a key compo- Another issue relating to a large number of cost centers
nent of total cost. Although not product cost is how to address (i.e., work areas).3 RCA requires
allowed for GAAP due to imme- idle capacity cost. Idle capacity tracking several cost categories
diate expensing of fixed over- in one period may be a necessary for each cost center, separating
head, the use of variable costing investment in another period to fixed and variable costs, and
can discourage buildup of inven- meet demand. Including these developing a cost rate for the
tories since fixed production costs as part of product costs, variable costs that can be used
costs are expensed instead of however, leads to the risk of a to charge costs to the output. A
being included in inventory. The “downward demand spiral.” This flexible budget is developed for
separation of fixed and variable term refers to decreasing demand each cost center based on the
costs permits construction actual activity volume.
of a “contribution margin” Fixed and variable costs
income statement. Contri- continue to be separated
bution margin equals sales Focusing on the contribution mar- as costs are rolled up to
minus all variable costs. gin may be relevant for short-term the final product cost. This
Focusing on the contribu- strategic decision making since fixed level of detail allows firms
tion margin may be rele- using RCA to achieve a
vant for short-term strategic overhead does not change signifi- high level of cost accuracy
decision making since fixed cantly with changes in short-term and control. This approach
overhead does not change is appropriate for batch
significantly with changes production volume. processing and when cost
in short-term production assignment drivers are
volume. quantifiable, but it can be
More inclusive methods expensive to implement.
include full absorption costing leading to allocating these costs Other methods between the two
discussed earlier and life-cycle to fewer products, which leads extremes include process cost-
costing. Life-cycle costing to higher cost allocations and ing, operation costing, and value
includes all production-related prices, which in turn leads to stream costing. Process costing
costs as well as nonproduction further decreased demand, and tracks costs at the process or
costs such as sales, administra- so forth. Many firms attempt to department level and assumes
tion, R&D, customer service, and report these idle capacity costs product uniformity. When prod-
disposal costs. These “upstream” separately in order to minimize ucts have certain unique costs
and “downstream” costs are part the impact of short-run capacity (e.g., different materials) but
of the overall value chain and are issues on product cost.2 essentially go through the same
increasingly being recognized as process, then a hybrid approach,
costs that need to be taken into At What Level of Detail Should called operation costing, is
account when making strategic We Track Direct Product appropriate.4 Value stream cost-
decisions. In fact, in many firms, Costs? ing is often associated with the
these costs are more significant Lean Accounting philosophy and
than manufacturing cost. Ignor- The second important ques- tends to be used with throughput
ing these costs can result in tion to answer is how to track costing. Value stream costing
understated product costs for direct product costs. As Exhibit 1 tracks revenues and costs by
strategic decision analysis. illustrates, one end of the spec- value stream (i.e., major flows
Exhibit 3
Definition Pr o s Cons
Throughput costing
Includes only direct Consistent with just- May lead to strategic
materials as product in-time and errors (e.g.,
costs discourages underpricing
Treats all other costs inventory buildup products)
as period costs Relatively simple Not allowed under
GAAP
Variable costing
Classifies cost by Allows cost-volume- May lead to strategic
behavior (e.g., profit (break-even) errors (e.g.,
variable or fixed) analysis underpricing
Treats variable products)
Consistent with a
manufacturing costs contribution margin Not allowed under
as product costs approach GAAP
Treats all other costs Relatively simple May require extra
as period costs training
Full absorption costing
Includes all materials, Required for GAAP Does not include
labor, and and IAS nonmanufacturing
manufacturing costs
Commonly used and
overhead as product
understood Can motivate
costs
unnecessary
Treats all other inventory buildup
nonmanufacturing
May treat fixed
costs as period costs
production costs as
variable
Life-cycle costing
Includes all Recognizes overall Downstream costs
production-related value-chain costs often not known
costs plus upstream
Best fit for long-term May treat all value
and downstream costs
product decisions stream costs as
as product costs (e.g.,
variable
R&D, customer
service, and disposal
costs)
of value-added activities that go accounting process by not track- cons for different approaches to
into delivering specific prod- ing costs for individual jobs or tracking direct product costs.
ucts and services to customers). processes. On the down side, it is
Sustaining costs are separated more challenging to apply in sit- How Do We Organize Indirect
from value stream costs to mini- uations where common resources Product Costs?
mize arbitrary allocations. Value are used to support multiple
stream costing works well in value streams. The question of how to
tandem with a Lean manufactur- Exhibit 4 provides a brief handle indirect costs is a key
ing strategy and simplifies the description and list of pros and challenge for product costing. By
Exhibit 4
Resource consumption
accounting (RCA)
Models how resources
are used by outputs
Responsibility for Typically requires
Separates costs into costs lies with cost expensive ERP
variable and fixed center managers system
elements for a large (strong cost control)
Very detailed—can be
number of cost
Highly accurate difficult to understand
centers
product cost
Typically most
Uses flexible information for short-
complex method
budgeting at the cost term decisions
center level
definition, these costs cannot be TDABC is the need to estimate with plantwide and department-
easily traced to the product (or the time to carry out each type of based cost pools. Unfortunately,
cost object). Exhibit 1 illustrates transaction and the assumption many cost categories are not cor-
a continuum of methods to track of constant time requirements. related with production volume.
indirect costs from simple to In addition, resource costs that In these cases, transaction-based
more complex methods (see are not correlated with time (e.g., cost drivers are more appropri-
Exhibit 5 for a list of pros and level of complexity, space, etc.) ate. Examples of transaction cost
cons for each method). His- may be handled more easily by drivers include number of set-
torically, most businesses have conventional ABC methods. ups, purchase orders, and design
chosen plantwide or department- The most complex method changes, which are commonly
based accumulation approaches to organize indirect costs is to used with ABC.
in which overhead costs are accu- use detailed cost centers. Often In other situations, dura-
mulated into either a single cost used with RCA, this method tion or intensity cost drivers are
pool or department-based cost tracks costs at the individual cost appropriate drivers. TDABC uses
pools. Departmental cost pools center (i.e., work area) level by duration drivers that measure the
are commonly used with opera- various categories (e.g., variable time required for a transaction.
tion and process costing methods. vs. fixed, supplies, labor, etc.). For example, assume it takes lon-
Although simple plantwide or These costs are “direct” to the ger to set up the melting pots for
department-based cost pools are cost center and then charged to a batch of organic chocolate bars
used extensively, prior research the product using the variable than for nonorganic bars. The
suggests that these approaches cost rate. Tracking these costs at chocolate factory may want to use
can lead to highly distorted setup hours rather than the
product costs due to the number of setups to allo-
inclusion of only one cost Although simple plantwide or cate setup costs. Intensity
driver. To address this drivers are more complex
issue, activity-based costing
department-based cost pools are used since they seek to measure
(ABC) organizes indirect extensively, prior research suggests the actual resources used by
costs by activity and can that these approaches can lead to an activity.6 For instance,
result in more accurate some products may be par-
product costs. ABC, how- highly distorted product costs due to ticularly difficult to set up
ever, has been criticized the inclusion of only one cost driver. because they require spe-
due to inherent complexity. cially trained workers and
Challenges include the dif- quality control personnel.
ficulty in collecting activ- Instead of treating all setup
ity data, allocation challenges, this disaggregated level allows hours alike, hours requiring dif-
and high implementation costs. for greater accuracy but at the ferent human resources would be
Time-driven ABC (TDABC) has expense of higher implementa- tracked separately. Use of inten-
been developed in response to tion and maintenance costs. sity drivers typically results in
these issues.5 TDABC attempts more accurate product costs but is
to simplify the ABC process by How Do We Allocate Indirect expensive to implement.
using time as the cost driver and Costs to Products?
thus skipping the activity defini- Taking Action
tion stage and surveying task. Closely related to deciding
Instead, just two parameters need how to track indirect costs is Developing the right product
to be estimated: (1) a capacity choosing the most appropriate costing system is not an easy or
cost rate for each department and basis for allocating these costs to trivial process. In order to find
(2) the typical capacity usage for the product. The goal is to find the right fit, first assess your
each type of transaction. By using the best “cost driver” for each current system based on conve-
a department’s total productive cost pool that approximates the nience, correctness, and costs of
time available as the denomina- cause-and-effect linkage between implementation. Also look for
tor when computing the capac- the costs and the product. As warning signs that your current
ity cost rate, TDABC allows Exhibit 1 shows, the simplest product cost system is flawed.
the firm to compute the cost of bases are related to volume (e.g., If the current system seems to
unused capacity. One downside of units produced)—typically used be consistently falling short,
Exhibit 5
consider the four key questions tem, but a firm can often quan- 2. See Kaplan, R., & Anderson, S.
and different approaches avail- tify the benefits for specific deci- (2007, March/April). The innovation
of time-driven activity-based costing.
able discussed in this article. sions and use them as examples. Cost Management, 21(2), 5–15. See also
Many of the approaches included In addition, employees whose Kren, L. (2008). Using activity-based
in this article fit well as a cost- measured performance is nega- management for cost control. Journal
ing package. For example, typi- tively affected by the new prod- of Performance Management, 21(2),
cal pairings include: throughput uct cost system may be wary of 18–28.
3. See White, L. (2009, May/June).
costing and value stream costing; system change. Being cognizant Resource consumption accounting:
department-based cost pools of potential behavioral issues is Manager-focused management account-
with process or operation cost- key in system implementation. ing. The Journal of Corporate Accounting
ing; plantwide cost pools with Back to Nestlé’s situation, & Finance, 20(4), 63–77; Krumwiede,
volume-based drivers; ABC with a careful examination of prod- K., & Suessmair, A. (2007). Getting
down to specifics on RCA. Strategic
transaction drivers; TDABC with uct costing systems resulted Finance, 88(12), 50–55; and Mackie, B.
duration drivers; and RCA with in a major system overhaul. (2006). Merging GPK and ABC on the
detailed cost centers. New information led to major road to RCA. Strategic Finance, 88(5),
Beyond the issues discussed changes in strategic direction. 33–39.
in this article, product costing For instance, CEO Peter Brabeck 4. See Pryor, T. (2010, January/February).
A financial thermometer for lean opera-
system change can result in chal- was surprised to discover that tions. Journal of Corporate Accounting
lenging behavioral and political it cost more to make flavored & Finance, 21(2), 81–91; and Kennedy,
issues. Even if improvements frozen treats in the United States F., & Brewer, P. (2005). Lean accounting:
to the cost systems are in order, than in Europe. In response, What’s it all about? Strategic Finance,
there is often resistance due to Nestlé retrained US factory 87(5), 27–34.
5. Kaplan, R., & Anderson, S. (2007).
financial and time constraints. workers to feed the machines The innovation of time-driven activity-
To help “sell” a cost system faster, leading to a 33 percent based costing. Cost Management,
improvement initiative to upper drop in the cost of ice pops the pp. 5–15. See also Öker, F., & Adigüzel,
management, try identifying following year. Nestlé discovered H. (2010). Time-driven activity-
some recent specific strategic or that good product management, based costing: An implementation in
a manufacturing company. Journal
operational decisions in which aided by better cost systems, can of Corporate Accounting & Finance,
cost information was used to pay major dividends. 22(1), 75–92.
help make the decision. Show 6. For a more complete discussion of dif-
how more accurate or complete ferent types of cost drivers, see Kaplan,
information might have altered NOTES R., & Cooper, R. (1998). Cost and effect:
Using integrated cost systems to drive
the outcome of the decision. It is 1. Ball, D. (2007, July 23). After buying profitability and performance. Boston,
hard to quantify the benefits of binge, Nestle goes on a diet. Wall Street MA: Harvard Business School Press;
improvements to a costing sys- Journal, p. A1. pp. 95–98.
Joseph G. Fisher is the Harry C. Sauvain Chair of the Department of Accounting in the Kelley School of
Business at Indiana University in Bloomington, Indiana. Kip Krumwiede is an associate professor in the
Department of Accounting in the Robins School of Business at the University of Richmond in Richmond,
Virginia.