In a recent post on the Evolving Excellence blog, Bill Waddell tackles one of my pet peeves: activity-based costing, or ABC. Few things do more harm to lean Six Sigma than this method of accounting. In fact, it is my opinion that the accounting systems used by U.S. businesses are responsible for a great deal of our country's declining economic prowess. Hindering improvement activities are just one example, but it's the example nearest to my heart.
Let me give you one example to illustrate (it would take a book to describe all that's wrong with ABC.) Let's say we are trying to convince Mary that lean Six Sigma is a great idea.
"Mary," we say enthusiastically, "using lean Six Sigma will help you reduce inventory. Inventory is a bad thing. It takes up valuable space, it hides quality problems, it costs money to build it and it doesn't generate any revenue..."
Mary nods in agreement and tells us to stop badgering her with the obvious. Furthermore, she adopts lean for several important product families and her inventories drop dramatically.
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ABC
JRomano
While I do not profess to be an MBA, I believe there are some inaccuracies in your article from the way I was taught ABC. ABC does not average overhead against items. An item made for inventory versus sale should have the activity cost of warehousing and storage; an item made for sale should not have those costs. A repeat sale item should not carry the cost of R&D versus a newly developed product. In my experience, most companies do not use ABC, it more difficult to track, computer costing systems do not account for most variations such as those noted above. If they were, six sigma costing would show immediate differences in the 'true' actual costs of producing an item for sale. Most companies today just smear costs across their product line which makes them less competitive and less understanding on how they actually made profit. It is very difficult to build R&D into the ABC cost model since few would be willing to pay the price for those first units (drug companies patents issues) versus generics. Please look at ABC as you would COQ.
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