Relevant Cost Analysis—Quality Improvements Destin Company produces water control valves, made of brass, which they sell primarily to builders for use in commercial real estate construction. These valves must meet rigid specifications (i.e., the quality tolerance is small). Valves that, upon inspection, get rejected are returned to the Casting Department, i.e., to stage one of the four-stage manufacturing process. Rejected items are melted and then recast. As such, no new materials in Casting are required to rework these items. However, new materials must be added in the Finishing Department for all reworked valves. As the cost accountant for the company, you have prepared the following cost data regarding the production of a typical valve:
Cost | Casting | Finishing | Inspection | Packing | Total |
Direct materials | $200 | $12 | $-0- | $8 | $220 |
Direct labor | 110 | 120 | 20 | 20 | 270 |
Variable manufacturing overhead | 100 | 150 | 20 | 20 | 290 |
Allocated fixed overhead | 70 | 80 | 40 | 1 0 | 200 |
| $480 | $362 | $80 | $58 | $980 |
The company, spurred by intense price pressures from foreign manufacturers, recently initiated a number of quality programs. As a result, the rejection rate for valves has decreased from 5.0 percent to 3.5 percent of annual output (equal in total to 15,000 units). The reduction in reject rates has enabled the company to reduce its inventory holdings from $400,000 to $250,000. Destin estimates that the annual financing cost associated with inventory holdings is 12 percent.
Required Provide a dollar estimate of the annual cost savings associated with the recently enacted quality improvements. Show calculations.
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