Question

TufStuff, Inc., sells a wide range of drums, bins, boxes, and other containers that are used in the chemical industry. One of the company’s products is a heavy-duty corrosion-resistant metal drum, called the WVD drum, used to store toxic wastes. Production is constrained by the capacity of an automated welding machine that is used to make precision welds. A total of 2,040 hours of welding time is available annually on the machine. Because each drum requires 0.4 hours of welding machine time, annual production is limited to 5,050 drums. At present, the welding machine is used exclusively to make the WVD drums. The accounting department has provided the following financial data concerning the WVD drums:

WVD Drums
Selling price per drum			$	157.00
Cost per drum:
Direct materials	$52.10
Direct labor ($20 per hour)	4.00
Manufacturing overhead	5.70
Selling and administrative expense	30.20			92.00
Margin per drum			$	65.00

Management believes 6,050 WVD drums could be sold each year if the company had sufficient manufacturing capacity. As an alternative to adding another welding machine, management has considered buying additional drums from an outside supplier. Harcor Industries, Inc., a supplier of quality products, would be able to provide up to 4,050 WVD-type drums per year at a price of $144 per drum, which TufStuff would resell to its customers at its normal selling price after appropriate relabeling.

Megan Flores, TufStuff’s production manager, has suggested that the company could make better use of the welding machine by manufacturing bike frames, which would require only 0.5 hours of welding machine time per frame and yet sell for far more than the drums. Megan believes that TufStuff could sell up to 1,640 bike frames per year to bike manufacturers at a price of $249 each. The accounting department has provided the following data concerning the proposed new product:

Bike Frames
Selling price per frame			$	249.00
Cost per frame:
Direct materials	$100.60
Direct labor ($18 per hour)	32.00
Manufacturing overhead	38.00
Selling and administrative expense	49.40			220.00
Margin per frame			$	29.00

The bike frames could be produced with existing equipment and personnel. Manufacturing overhead is allocated to products on the basis of direct labor-hours. Most of the manufacturing overhead consists of fixed common costs such as rent on the factory building, but some of it is variable. The variable manufacturing overhead has been estimated at $1.35 per WVD drum and $1.90 per bike frame. The variable manufacturing overhead cost would not be incurred on drums acquired from the outside supplier.

Selling and administrative expenses are allocated to products on the basis of revenues. Almost all of the selling and administrative expenses are fixed common costs, but it has been estimated that variable selling and administrative expenses amount to $.75 per WVD drum whether made or purchased and would be $1.50 per bike frame.

All of the company’s employees—direct and indirect—are paid for full 40.00-hour work weeks and the company has a policy of laying off workers only in major recessions.

As soon as your analysis was shown to the top management team at TufStuff, several managers got into an argument concerning how direct labor costs should be treated when making this decision. One manager argued that direct labor is always treated as a variable cost in textbooks and in practice and has always been considered a variable cost at TufStuff. After all, “direct” means you can directly trace the cost to products. “If direct labor is not a variable cost, what is?” Another manager argued just as strenuously that direct labor should be considered a fixed cost at TufStuff. No one had been laid off in over a decade, and for all practical purposes, everyone at the plant is on a monthly salary. Everyone classified as direct labor works a regular 40.00-hour workweek and overtime has not been necessary since the company adopted Lean Production techniques. Whether the welding machine is used to make drums or frames, the total payroll would be exactly the same. There is enough slack, in the form of idle time, to accommodate any increase in total direct labor time that the bike frames would require.

5. Compute the contribution margin per unit. [assume direct labor is a variable cost]

6. Compute the contribution margin per welding hour. [assume direct labor is a variable cost]

7. Assuming direct labor is a variable cost:

a. Determine the number of WVD drums (if any) that should be purchased and the number of WVD drums and/or bike frames (if any) that should be manufactured. [Assume direct labor is a variable cost]

b. What is the increase (decrease) in net operating income that would result from this plan over current operations?

Answer 1

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Tufstuff Inc.
Answer 5	Purchase Drums	Manufacture Drums	Manufacture Bike Frames	Note
Sell price	157.00	157.00	249.00	See A
Less: Variable costs
Purchase Price	144.00
Direct Material		52.10	99.40
Direct Labor		4.00	28.80
Manufacturing overhead		1.35	1.90
Selling & Admin	0.75	0.75	1.50
Total Variable costs	144.75	58.20	131.60	B
Contribution per unit	12.25	98.80	117.40	C=A-B
Answer 6	Manufacture Drums	Manufacture Bike Frames	Note
Contribution per unit	98.80	117.40	See C
Welding hour per unit	0.40	0.50	See D
Contribution per Welding hour	247.00	234.80	E=C/D

Workings for Answer 7

Contribution per Welding hour of Drums is higher than Bike Frames. So entire welding hours should be used for Drums and remaining demand of drums should be fulfilled by buying it from outside supplier.

Calculation of fixed costs	Drums	Note
Annual production	5,050.00	F
Manufacturing overhead	5.70
Less: Variable Manufacturing overhead	1.35
Fixed Manufacturing overhead per unit	4.35	G
Total Fixed Manufacturing overhead	21,967.50	H=F*G
Selling & Admin	30.20
Less: Selling & Admin	0.75
Fixed Selling & Admin per unit	29.45	I
Total Fixed Selling & Admin	148,722.50	J=F*I
Current Net Income	Amount $
Drums sold	5,050.00	See F
Margin per drum	65.00	K
Current Net Income	328,250.00	L=F*K

Revised Net Income	Purchase Drums	Manufacture Drums	Total	Note
Units sold	1,000.00	5,050.00		M
Contribution per unit	12.25	98.80		C
Total Contribution	12,250.00	498,940.00	511,190.00	N=M*C
Less: Fixed costs
Total Fixed Manufacturing overhead			21,967.50	See H
Total Fixed Selling & Admin			148,722.50	See J
Total Fixed costs			170,690.00	O=H+J
Revised Net Income	12,250.00	498,940.00	340,500.00	P=N-O
Increase in net income			12,250.00	Q=P-L