1. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 1 Outline Questions, Comments? Take roll Analysis of Costs Databases Production Environments First quiz on Thursday a week from now

2. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 2 Costs of Products and Services What information do we need to determine cost?

3. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 3 Planned Components of Cost In order to establish the internal cost of a product or service, we consider the following components: Direct labor - any activity that touches the product Indirect labor - any activity in support of the product that does not touch the product Indirect costs - expenses necessary to conduct business, such as utilities Material - parts or material purchased from outside suppliers Material overhead - activities that support the acquisition and movement of materials used in producing the products Note = cost is not equal to price! Price is usually a function of demand and competition.

4. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 4 Indirect Costs Rent Utilities Depreciation (large investments must be deducted from taxes over their lifetime) Consumable materials Freight Insurance Taxes Management Information Systems Corporate allocations

5. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 5 Material Overhead Purchasing Warehousing Movement of material Inspection Supplier support activities Inventory carrying costs (range as high as 25% of the value of the part per year) Shipping

6. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 6 Indirect Labor Personnel (Human Resources) Finance Management Engineering Facilities Maintenance

7. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 7 Adding up the costs (example) A plant generates 270,000 earned hours per year (established by standards for each of the products produced). 85% efficiency is assumed. The cost of an hour of labor, including benefits, is $30 Indirect labor totals $30M per year Materials cost $70M per year Material overhead costs are $4M per year What is the cost of a product containing 0.8 hours of standard labor and $20 of material? We first calculate the total labor rate as (30,000,000+270,000*30/0.85)/270,000=$146.40/hour

8. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 8 Adding up the costs (example continued) Material overhead = $4M/$70M= 5.7% Direct and indirect labor =0.8* $146.40=$117.12 Material=$20.00 Material Overhead= 0.057*20=$1.14 Total Cost =$138.26 We can separate the direct and indirect labor into: Direct labor = 0.8*30=$24 Indirect=$93.12 And you can see why everyone attacks overhead If you are independent, the profit would add another 10% or so. It is very dependent on the industry and level of investment

9. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 9 Cost Distribution

10. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 10 Access Data Base

11. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 11 Parts File Parts, alphabetical 20-Jan-04 Part IDDescriptionUOMLead Time (Weeks) ALUM-HSAluminum High StrengthEACH2 ALUM-XSAluminumEACH3 BAGMC10EACH0 BAGMC75EACH0 BAGMM25EACH0 BAGMM85EACH0 BAR-01Bar Stock 1"EACH0 BAR-02Bar Stock 2"EACH0

12. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 12 Bill of Materials

13. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 13 Work Centers

14. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 14 Purchasing

15. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 15 Routings

16. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 16 Demand

17. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 17 Work Centers making parts – derived report

18. Session 2 University of Southern California ISE514 August 25, 2016 Geza P. Bottlik Page 18 Production Environments Make to Stock Assemble to Order Make to Order Engineer to order