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    AgriCo's Service Division JIT inventory program: savings and

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    Michael Chang, manager of AgriCo's Service Division, dialed the division controller's number on his phone "Janice, this is Mike Chang, How's that JIT program doing? Has it saved us any money? I've got to report to the president next week, and I'd like to know how our inventory efforts are coming along". "Give me a day or two, Mike, and I'll have some figures for you," responded Janice Patel, the division controller.

    AgriCo is a manufacturer of farm equipment sold by a network of distributors throughout North America. A majority of the distributors are also repair centers for AgriCo Service Division to provide timely support of spare parts. In an effort to reduce the inventory costs incurred by the Service Division Chang implemented a just-in-time inventory program on January 2, 2xxx. JIT has now been in operation for a year. Grady has been able to document the following results of JIT implementation.

    * The service Division's average inventory declined for $550,000 to $150,000
    * Projected annual insurance costs of $80,000 declined by 60 percent due to the lower average inventory
    * A leased, 8,000 square foot warehouse previously used for raw material storage, was not used at all during the year. The division paid $11,200 annual rent for the warehouse and was able to sublet three-quarters of the building to several tenants at $2.50 per square foot. The balance of the space remained idle.

    *Two warehouse employees whose services were no longer needed were transferred on January 2, 2xxx, to the Purchasing Department to assist in the coordination of JIT program. The annual salary expense for these two employees totaled $38,000 and continued to be charged to the indirect labor portion of fixed overhead.

    * Despite the use of overtime to manufacture 7,500 spare parts, lost sales due to stock outs totaled 3,800 spare parts. The overtime premium incurred amounted to $5.60 per part manufactured. The use of overtime to fill spare parts orders was immaterial prior to January 1, 2xxx.

    Prior to the decision to implement the JIT inventory program, AgriCo's Service Division had completed its 2xxx budget. The division's budgeted income statement, without any adjustments for just-in-time inventory, follows. AgriCo's incremental borrowing rate for inventory is 15 percent. Taxes are ignored.

    AGRIC SERVICE DIVISION
    Budgeted Income Statement
    For the Year Ended December 31, 2xxx (in thousands)
    Sales (280,000 spare parts).................................... $6,160
    Cost of goods old:
    Variable.................................$2,660
    Fixed....................................1,120 3,780
    Gross margin.....................................................2,380
    Selling and administrative expenses:
    Variable.................................$700
    Fixed.....................................555 1,255
    Operating income................................................$1,125
    Other income........................................................75
    Income before interest and income taxes..........................$1200
    Interest expense...................................................150
    Income before income taxes.......................................$1050

    1. Calculate the cash saving (loss) for AgriCo's Service Division that resulted during 2xxx from the adoption of the JIT inventory program. Contribution margin is the sales revenue minus the variable cost.

    2. Discuss any factors, other than financial, that should be considered before company implements a JIT program.

    3. Build a spreadsheet: Construct an excel spreadsheet to solve requirement (1) above. Show how the solution will change if the following information changes: the Service Department's average inventory declined to $200,000 and projected annual insurance costs declined by 50 percent.

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    Solution Preview

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    Cost savings (loss) from JIT Inventory program are listed below:
    1. Decrease in investment cost in inventory 60000
    2. Savings in insurance cost 48000
    3. Savings from decrease in warehouse usage 15000
    4. Transferred employee cost 0 No real savings as the employees were used elsewhere for JIT work.
    5. Overtime premium -42000
    6. Loss of contribution due to stockout -38000
    Net Savings due to ...

    Solution Summary

    This post conducts a comprehensive analysis of the JIT inventory management program for AgriCo case. The students will learn how to do the cost benefit analysis for investments in new management systems.

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