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Statements on Management Accounting

STRATEGIC COST MANAGEMENT

TITLE

Tools and Techniques


for Implementing
Target Costing

CREDITS

This statement was approved for issuance as a Special thanks go to Randolf Holst, CMA, Knowledge
Statement on Management Accounting by the Manager at Arthur Andersen, for his continuing over-
Management Accounting Committee (MAC) of the sight during the development of the Statement. IMA
Institute of Management Accountants (IMA®). IMA thanks the Consortium for Advanced Manufacturing-
appreciates the collaborative efforts of the Cost International (CAM-I) for their support in the develop-
Management Competency Center at Arthur Andersen ment of this SMA. IMA is also grateful to the members
LLP and the work of Dr. C.J. McNair, CMA, of Babson of the Management Accounting Committee for their
College, who drafted the manuscript. contributions to this effort.

Published by
Copyright © 1998 in the United States
Institute of Management Accountants
of America by Institute of Management
10 Paragon Drive
Accountants and Arthur Andersen LLP
Montvale, NJ 07645
www.imanet.org All rights reserved
IMA Publication Number 98355 ISBN 0-86641-272-7
Statements on Management Accounting

STRATEGIC COST MANAGEMENT

Tools and Techniques for Implementing


Target Costing

TABLE OF CONTENTS

I. Rationale . . . . . . . . . . . . . . . . . . . . . . . 1 Exhibits
II. Scope . . . . . . . . . . . . . . . . . . . . . . . . . 1 Exhibit 1: Target Costing Process Steps . . .3
III. The Role of Management Accounting . . . .1 Exhibit 2: QFD Matrix in Product Planning
IV. Target Costing Process Steps . . . . . . . . .3 of a Fax Machine . . . . . . . . . . . . .5
V. Implementation Tools and Techniques . . .3 Exhibit 3: Product Design Process Chart . . .6
Exhibit 4: Hierarchy of Defined Criteria . . . .8
Product Planning Phase
Exhibit 5: Determining the Priority of Criteria 9
Establishing the Target Market Price . . . . .3 Exhibit 6: Ranking Customers by Criteria . . .9
Establishing the Target Profit Margin Exhibit 7: Voice of Customer Analysis Table 10
and Cost to Achieve . . . . . . . . . . . . .12 Exhibit 8: Ratings within a Customer Voice
Calculating the Probable Cost of Analysis . . . . . . . . . . . . . . . . . .11
Current and New Products and Exhibit 9: Relationship Matrix . . . . . . . . . .12
Processes . . . . . . . . . . . . . . . . . . . .14 Exhibit 10: Target Costing and Profit
Establishing the Target Cost . . . . . . . . .20 Management Process . . . . . . . .13
Exhibit 11: Multi-Year Product/Profit Plan . . .15
Product Design and Development Phase
Exhibit 12: Rate Master List for Process
Attaining the Target Cost . . . . . . . . . . . .22 Costs . . . . . . . . . . . . . . . . . . . .16
Production Phase Exhibit 13: Component Cost Analysis . . . . .17
Pursuing Cost Reductions Once Exhibit 14: Component Cost Breakdown . . .18
Production Has Started . . . . . . . . . . .26 Exhibit 15: Cost Table Structure . . . . . . . . .19
VI. Conclusion . . . . . . . . . . . . . . . . . . . . .29 Exhibit 16: Benchmarking Steps . . . . . . . . .21
Exhibit 17: Computing the Cost Gap . . . . . .23
VII. Bibliography
Exhibit 18: Boeing DFMA Application
Results Summary . . . . . . . . . . .25
Exhibit 19: Value Engineering (VE)
Framework . . . . . . . . . . . . . . . .26
Exhibit 20: Value Engineering (VE) Ideas to
Reduce Costs . . . . . . . . . . . . . .27
Exhibit 21: Relationships between ABC, ABM,
and Target Costing . . . . . . . . . .28
STRATEGIC COST MANAGEMENT

I . R AT I O N A L E tions. It supplements the Institute of Manage-


Today, competition among companies in many ment Accountants’ Implementing Target Costing,
industries is turning global. The companies com- published in 1998, which describes the target
peting in this global market are now in a highly costing process, as well as Target Costing—The
competitive race in terms of quality levels, and to Next Frontier in Strategic Cost Management, pub-
get ahead each company must come up with lished by the Consortium for Advanced
technological innovations. Because technologi- Manufacturing-International (CAM-I) in 1997.
cal innovation has become a key part of this
race, competing companies are also faced with The focus of this publication is on core tools and
severe “cost competition” as they seek to pro- techniques that improve the effectiveness of tar-
vide customers with desired quality at an afford- get costing. The focus is on core tools because
able cost. it is beyond the scope of this guideline to dis-
cuss all the tools and techniques that support
Thus, for companies to survive, they must now the implementation of target costing.
set prices that are competitive in today’s market
while also setting costs that allow a sufficient This SMA assumes the reader is already familiar
profit margin. As prices are increasingly deter- with basic target costing concepts. It is intended
mined by market competition, costs must be for organizations that have already decided to
carefully managed to create profits. implement target costing. The tools and tech-
niques discussed apply to:
New forms of management tools and techniques
are emerging to help managers take on this dif- ● all levels of an enterprise;
ficult task. Primary among these new approach- ● all functions of an enterprise;
es is target costing. Driven by the voice of the ● enterprises in all business sectors; and
customer to better understand what product and ● small and large organizations.
service attributes are needed, target costing
becomes the means to long-term growth This guideline will be useful to those who may
attained by doing what the customer wants, bet- lead or participate in efforts to implement target
ter and faster than the competition. costing. It will help them to:

An organization that implements and masters ● develop a framework for planning and manag-
target costing will continuously be ahead of the ing the implementation of target costing;
competition as it fine-tunes its integral efforts to ● learn about the various core tools and tech-
those most likely to be rewarded by the market. niques to improve the effectiveness of target
It is key to proactively building a competitive costing; and
advantage. ● understand the roles and responsibilities of
financial professionals in the target costing
II. SCOPE process.
This Statement on Management Accounting
(SMA) is addressed to financial professionals III. THE ROLE OF MANAGEMENT
and others who may lead or participate in efforts ACCOUNTING
to implement target costing in their organiza- Target costing is an integrative approach to

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product design and development that requires the target costing process;
the active and ongoing participation of individu- ● developing ongoing product cost systems that
als from across the organization. It builds from will tie in with continuous improvement goals
a sound understanding of current costs, trade- for the product launch;
offs among cost, quality, and functionality, and ● supporting development of target price and
the changing requirements of customers. It profit projections, including assuring that the
serves to coordinate design team efforts, com- numbers are objective, reliable, and accurate;
municate needs to all involved parties, and and
clearly define the overall objectives and chal- ● serving on the product design team to provide
lenges facing the organization during product expertise to support pre- and post-launch man-
launch and maintenance. agement of the product within target-cost-
defined parameters.
Within this customer-driven, product-focused
environment, financial professionals provide the In target costing, the financial professional
technical expertise required to ensure that the serves as a team member with unique econom-
defined costs are reliable, that the trade-offs ic expertise that can help to develop prelimi-
being made meet basic functionality and quality nary cost estimates, validate assumptions
requirements, and that economic analysis is using current and historical cost databases,
used as the basis for key decisions. The role of and analyze the impact of various alternatives
the financial professional in implementing target on the product/service costs. New forms of
costing includes the following efforts and cost information are used to accomplish many
objectives: of these tasks:

● ensuring that the target costing initiatives are ● Life-cycle costing accumulates and analyzes
based on strategic criteria and are designed to product costs from birth to death of a product
support company objectives; using the life stages of a product as the struc-
● providing economic expertise where needed to turing cost object.
prioritize and assess specific product or ser- ● Value-chain costing integrates cost information
vice attributes; across traditional organizational boundaries to
● creating a system of financial and performance include suppliers, dealers, and customers. It
measurements that support ongoing monitor- focuses attention on the cost and contribution
ing of pre- and post-launch activities against required from each value-chain member toward
objectives set during the target costing the achievement of target cost and strategic
process; objectives.
● providing historical costs and estimated future ● Feature/function costing requires the decom-
costs for specific product or service attributes; position and assignment of cost reduction tar-
● identifying gaps in current versus required gets to product components based on their
costs and functionality, and developing eco- relationship to customer requirements and the
nomic and performance-based assessments relative importance of these needs.
of the impact of these gaps; ● Design driver costing focuses attention on the
● ensuring that internal and external information impact of design on life-cycle and value-chain
is validated and analyzed prior to use within costs, as well as the impact of changes in prod-

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EXHIBIT 1. TARGET COSTING PROCESS STEPS

uct attributes on the final cost of the product. include most or all six steps outlined in Exhibit
● Operations costing provides cost information 1, although not necessarily in the order pre-
on a particular manufacturing operation. sented. Keeping this in mind, the six basic
● Activity-based costing identifies the drivers of steps involved in implementing target costing
indirect manufacturing, marketing, and sup- are:
port costs. It focuses attention on how product
designs lead to the consumption of various ● establishing the target market price;
activities, which in turn creates cost. ● establishing the target profit margin and cost
to achieve;
Tightly linked to the other cost management ● calculating the probable cost of current and
tools, target costing is an important means by new products and processes;
which finance professionals can help their ● establishing the target cost;
organization avoid future costs. This proactive ● attaining the target cost; and
position provides for optimal impact as well as ● pursuing cost reductions once production has
creates a solid platform for the inclusion of finan- started.
cial professionals on teams charged with devel-
oping, managing, and measuring product or ser- While organizations can modify these core activ-
vice performance. ities to meet a particular situation, they are rec-
ommended as a guide for structuring the imple-
I V. TA R G E T C O S T I N G P R O C E S S mentation of target costing initiatives.
STEPS
The target costing process has six key steps. V. I M P L E M E N TAT I O N T O O L S A N D
These steps, along with the pre-project prepara- TECHNIQUES
tion, represent a standard work plan, a frame- Establishing the Target Market Price
work for training, and implementation. While Cost considerations play a minor role, at best, in
each target costing initiative is unique, an orga- determining the target price under target cost-
nization’s actual implementation will likely ing. Instead, target costing uses product or ser-

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vice features1 to identify a target market price. ensure that everyone is working toward the
Driven by the market, and by expected relation- same objectives and outcomes.
ships between supply, demand, and price sensi-
tivity for the product, the determination of the tar- QFD brings together the relationships between
get market price incorporates several objectives, competitive offerings, customer requirements,
including: and design parameters, through a set of matri-
ces. These matrices are used iteratively through-
● identifying market and customer wants and out the target costing process. In the product
needs; planning phase, these matrices help determine
● determining how much customers are willing exactly what the customer desires, how well
to pay for alternative features; competitors are satisfying the customer, and
● transforming the desires of the customer/user where unfulfilled niches exist in the marketplace.
into the language required to implement a A QFD matrix developed for the product planning
product; and phase of a fax machine is shown in Exhibit 2.
● assessing what the competitive offerings are.
This matrix summarizes information about prod-
At the heart of the target-price-setting process is uct functions and their associated customer
the concept of perceived value. Customers can rankings. It also shows the correlation between
be expected to pay more for a new product than competitor design parameters and customer
its predecessor, but only if its perceived value is requirements. Additionally, information is provid-
greater. Understanding what attributes lead to ed about how customers evaluate competitor
specific value, and therefore price, is an essen- offerings on these same features. The QFD
tial part of setting a market price that yields opti- matrix shows that the customer requirement of
mal return for the organization’s efforts. These receive/send speed has a high correlation with
objectives can be achieved by applying several the design of modem speed and memory.
tools and techniques, including: Similarly, printing speed is correlated to the print
engine design parameters.
● quality function deployment;
● analytic hierarchy process; QFD is used successfully by both product- and
● customer voice analysis; and service-based organizations. For example, it has
● relationship matrix. been used in the manufacture of automobiles,
electronics, home appliances, clothing, integrat-
Quality Function Deployment ed circuits, synthetic rubber, construction equip-
Since customers often make fairly subjective ment, and agricultural engines. QFD has also
statements when evaluating a product, quality been used to design retail outlets, schools, and
function deployment (QFD) is a methodology use- plant layouts.
ful for translating customer preferences system-
atically into a number of objective design require- Exhibit 3 provides a summary of the critical
ments. These requirements can then be commu- processes, tasks, responsibilities, and stages
nicated to the design and production teams to involved in QFD. Columns represent the organiza-

1 A feature is a physical or aesthetic attribute of the product desired by the customer. Decomposing a target cost by product
features allows organizations to view these costs from a customer’s perspective.

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EXHIBIT 2. QFD MATRIX IN PRODUCT PLANNING OF A FAX MACHINE

Source: Ansari, et al., 1996: 152.

tion’s functional units, while rectangles in the Using the QFD methodology, a model is devel-
flowchart identify activities and required interde- oped that consists of the following:
partmental participation. Arrows indicate the
flow of documents or decisions. ● An Objective Statement, a description of the
goal, problem, or objective of the team effort;
The chart defines QFD team structure as well as ● The Whats, a list of characteristics of a product,
the core documents and information the team process, or service, as defined by customers;
will require to complete tasks. Serving as a road ● Importance Ratings, or weighted values assigned
map for managing a QFD project, the chart helps the Whats, indicating relative importance;
an organization identify and answer several core ● A Correlation Matrix, which shows the relation-
questions in the planning and design process, ship between the Hows;
including which customers are being empha- ● The Hows, ways of achieving the Whats;
sized, what their demands are, how much one ● Target Goals, indicators of whether the team
customer segment’s requirements should drive wants to increase or decrease a How or set a
the design process, and what criteria should be target value for it;
used to make these decisions. ● A Relationship Matrix, a systematic means for

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EXHIBIT 3. PRODUCT DESIGN PROCESS CHART

Source: Terninko, 1997: 27.

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identifying the level of relationship between a tion in start-up costs on the launch of the new
product/service characteristic What and a way van in October 1979, a 38 percent reduction in
to achieve it, the How; November 1982, and a cumulative 61 percent
● Customer Competitive Assessment, a review of reduction in April 1984. During this period, the
competitive products/service characteristics in product development cycle (time to market) was
comparison with the team’s product or service; reduced by one-third with a corresponding
● Technical Competitive Assessment, the organiza- improvement in quality due to a reduction in the
tion’s engineering specifications for each How number of engineering changes.
and the competitor’s technical specifications;
● Probability Factors, values indicating the ease Analytic Hierarchy Process
with which the organization could achieve each The analytic hierarchy process (AHP) is a multi-
How; criteria, decision-making technique that com-
● Absolute Score, the sum of the calculated val- bines qualitative and quantitative factors in the
ues for each How or column in the Relationship overall evaluation of alternatives. AHP is an
Matrix; and excellent tool for considering different character-
● Relative Score, a sequential numbering of each istic combinations of customer segments. By
How according to its Absolute Score. Number examining these characteristics, an organization
one is entered for the How with the highest can uncover new market segments and deter-
score, two for the next highest, and so on. mine the relative importance of each.

QFD methodology provides a framework for clari- The AHP methodology comprises four steps:
fying and meeting goals. For decision makers, it
helps them identify what is important by provid- ● building a decision hierarchy by breaking the
ing a fact-based system to replace emotion- general problem into individual criteria;
based decision making. The uniqueness of the ● gathering relational data for decision criteria
methodology is that this data can be captured and encoding them using the AHP relational
and strategically evaluated in the initial days of scale;
decision making. This is when decisions are ● estimating the relative priorities (weights) of
made on whether to proceed with production or decision criteria and alternatives; and
service development. QFD helps organizations ● performing a composition of priorities for the
identify what will work, what will not work, and criteria that gives the rank of alternatives rela-
what things should be avoided. Since as much tive to the top-most objective.
as 80 percent of the project’s cost is locked in
during this early phase, this assessment can AHP begins with subject matter experts building
greatly reduce program costs and development a hierarchical representation of the decision
time. problem. At the top of this hierarchy is the over-
all objective, and the decision alternatives are at
For example, Toyota has used QFD since 1977. the bottom. Between the top and bottom levels
The results have been impressive. Between are the relevant attributes of the decision prob-
1977 and 1994, Toyota Autobody introduced lem that provide significant input to the decision
four new van-type vehicles. Using 1977 as the process. The hierarchy can be quite detailed,
base year, Toyota reported a 20 percent reduc- though most applications need no more than

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EXHIBIT 4. HIERARCHY OF DEFINED CRITERIA

three levels, as shown in Exhibit 4. of the characteristic as a percentage of the total


for each column). The average of the normalized
Once the levels and elements have been deter- scores in the rows ranks the importance of the
mined, the subject matter experts assign relative criteria. As shown in Exhibit 5, market size, cost
weights to each defined characteristic using a to support, ease to satisfy, and publicity are
consensus method based on the following nine- 0.604, 0.119, 0.066, and 0.211, respectively.
point scale of importance. Market size is nearly three times more important
than publicity.
1. Equal importance—the row and column have
the same impact upon the higher order need. Once key criteria are identified, potential cus-
2. Between 1 and 3. tomers can be ranked, as illustrated in Exhibit 6.
3. Moderate importance—experience and judg- The left two columns show the criteria and their
ment slightly favor the row over the column. calculated weights. The importance of each cus-
4. Between 3 and 5. tomer for each criterion is recorded in the next
5. Strong importance—experience and judg- three columns. The weighted importance of each
ment strongly favor the row over the column. customer for each criterion is the product of the
6. Between 5 and 7. importance of the criterion and the importance
7. Very strong importance—the row is strongly of each customer for that criterion. The column
favored and its dominance is demonstrated totals are the weighted importance for each of
in practice. the customers. The exhibit illustrates that the
8. Between 7 and 9. market size criterion is the most important and
9. Extreme importance—the evidence favoring the consultant is the most desirable customer
the row is of the highest possible order of for this criterion. By helping organizations deter-
affirmation. mine the relative importance of customer seg-
ments, AHP allows firms to better determine
Using a series of calculations, a resulting two- whom to talk to and how much weight to assign
way comparison table is normalized (the fraction to their opinions.

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EXHIBIT 5. DETERMINING THE PRIORITY OF CRITERIA

Source: Terninko, 1997: 41.

Customer Voice Analysis bring forth the wrong product or service.


Customer voice analysis helps an organization to Therefore, obtaining the voice of the customer
better understand customers’ expectations, accurately is critical.
voiced desires, and as yet unperceived needs.
These qualities, or attributes, become the Customer voice analysis aids the development
“whats” of QFD—the individual characteristics of of an accurate list of product or service charac-
the product or service that drive customer satis- teristics. As illustrated in Exhibit 7, customer
faction and value perceptions. If an inaccurate voice analysis makes the list of “whats” more
representation of customer desires is obtained, manageable, focuses the QFD process, and
the QFD process will fine-tune the system to helps clarify meanings.

EXHIBIT 6. RANKING CUSTOMERS BY CRITERIA

Source: Terninko, 1997: 46.

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EXHIBIT 7. VOICE OF CUSTOMER ANALYSIS TABLE

Source: Terninko, 1997: 54.

Once the primary list of “whats” is identified, reduced selling price, Puritan-Bennett took away
attention turns to rating these qualities system- the competitor’s price edge and fulfilled a need
atically. The resulting rankings play a key role in that neither company had previously satisfied.
the QFD process, serving as weighting factors
that are used downstream as multipliers for Relationship Matrix
other analysis. It is critical that these rankings A relationship matrix focuses attention on how
accurately reflect the customers’ opinions. the various customer requirements will be met
Exhibit 8 provides an illustration of the delivery using tangible and intangible product or process
qualities and their rankings for a large aerospace characteristics. Since many customer require-
company. ments are too unclear or poorly defined to pro-
vide guidance to the organization, they must be
Puritan-Bennett used customer voice analysis to changed into the language of engineering.
develop a new spirometer. Information about Performance or technical measurements evalu-
customer demands came from physicians and ating the product’s performance, based on
nurses, supplemented by dealer and distributor demanded quality, are used for this purpose.
input. During the design process, there were
many lively discussions over which engineering At least one quantifiable performance measure
solution a product feature should use. Customer is typically identified for each demanded quality.
voice analysis ensured that decisions always For instance, if the demanded quality for an
favored the customer. With a better design and easel pad includes “stay on wall,” two perfor-

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EXHIBIT 8. RATINGS WITHIN A CUSTOMER VOICE ANALYSIS

Source: L. Guinta and N. Praizler, 1993: 55.

mance measures can be envisioned: “time on customer’s satisfaction with the product’s ability
walls” and “number of walls.” Test procedures to satisfy demanded quality Y?
can then be developed to understand how long
the product remains on a variety of different wall Four options are offered in the example illustrat-
surfaces. ed in Exhibit 9: a strong relationship, a medium
relationship, a weak relationship, and no rela-
Defining how well performance measures that tionship. The use of symbols for these weight-
detail the technical features of the product will ings, similar to a Consumer Reports evaluation
relate to the demanded qualities is key to trans- model, facilitates the identification of patterns of
forming customer information into specific, relationships in the matrix.
objective design language. Without this transfor-
mation, product characteristics and potential Important demanded qualities should have a per-
“price-creating” value cannot be used to drive formance measure with at least a medium rela-
internal efforts. tionship. Relatedly, more than 50 percent of the
cells should represent no relationship, in keep-
A relationship matrix details the strength of each ing with the Pareto principle that most of the
performance measure in terms of its predictive value will come from the critical few qualities and
ability for each customer-demanded quality. For measures. If a row is blank in the relationship
each row demanded quality and column perfor- matrix, it means that the demanded quality will
mance measure intersection, the following ques- not influence the design. This could be a critical
tion should be asked: If I know the value for per- omission. A blank column, on the other hand,
formance measure X, how well will it predict the indicates that resources would be wasted meas-

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EXHIBIT 9. RELATIONSHIP MATRIX

Source: Terninko, 1997: 90.

uring something that does not directly satisfy least amount of variety and complexity in the
customer needs. final product design.

Narrowing the total list of potential measures to Establishing the Target Profit Margin
the critical few is important in order to focus and Cost to Achieve
design efforts and ensure that the needs of tar- After the target price is set, the focus shifts to
get customers are met. If multiple customer seg- establishing the target profit margin and specifi-
ments are to be addressed, the answers to cation of the achievable cost objective. The over-
these questions can be expected to differ by seg- all goal is to ensure that the profitability and
ment. The final choice of performance criteria return on investment goals of the organization
will then need to be adjusted to accommodate are met by the new product or service. Specific
the optimal level of satisfaction for the largest objectives of this phase include:
number of potential customers, incorporating the

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EXHIBIT 10. TARGET COSTING AND PROFIT MANAGEMENT PROCESS

Source: Monden, 1995: 50.

● determining return on sales objectives; and get profit margins for product line models and
● linking capital investment planning to prof- the various strategic project plans that together
itability and the costs associated with product make up the organization’s basic management
development and delivery. structure must be determined. Strategic project
plans include new product development plans for
The long-term general profit plan of the organiza- each product or service, plant investment plans,
tion is the backdrop for the development of and capital procurement plans. New product
product-line-specific objectives. Specifically, tar- development plans are required for each year of

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the projected product life. sonnel capacity (for design, prototype develop-
ment, and production setup work), manufactur-
For example, at Nissan, the corporate develop- ing plant capacity, and new plant investment
ment plan coordinates the new-product life-cycle capacity (including capital procurement ability).
plans for each vehicle model with long-term prof-
it plans as part of the long-term profit planning Outputs:
process. Corporate new-product development ● multi-year general profit plan (exact timeframe
plans are required for each year in the projected varies by the nature of the planning cycle in a
product life and cover all full model changes or given industry);
minor changes that are planned for all target ● products/services to be developed and intro-
models. Thus, all production and sales plans for duced over a certain time period;
the company’s vehicle models are coordinated ● target profit for each product or product series;
under one plan that takes the perspective of the ● target return-on-sales ratio for each product;
company’s overall business strategy. ● plant investment plan for each product;
● personnel plan; and
Coordinating all of an organization’s production ● overall new product introduction plan.
and sales plans ensures that these efforts
reflect the strategic business perspective. Exhibit 11 illustrates a multi-year product/profit
Exhibit 10 details the role of the target profit plan structure. It is an annual product mix that
management process within a target costing sys- shows aggregate target profits by year for each
tem of a major automobile manufacturer. product. The sum of all products in a given year
is the annual profit plan, while the total of annu-
Target profit margins must be realistic and suffi- al profits by products is the product life-cycle
cient to offset the life-cycle costs of the product. profit. The product level profit includes all direct-
A useful tool used for establishing target profit ly traceable recurring costs (such as materials)
margins is a multi-year product/profit plan. and conversion, and nonrecurring traceable
costs (such as special tooling and dedicated
Multi-Year Product/Profit Plan machinery and other costs.)
A multi-year product/profit plan integrates the
various product plans, establishes baseline tar- Having laid out the parameters for an individual
gets for each product over its useful life, and product within the context of the overall compa-
ensures that the timing of new product releases ny strategic profit and product plans, attention
are staggered to prevent bunching, while sup- can turn to calculating the probable cost of cur-
porting the effective use of company resources. rent and new products and processes.
The plan has a series of inputs and outputs,
specifically: Calculating the Probable Cost of Current
and New Products and Processes
Inputs: A key step in the product planning phase
● life-cycle plans for the proposed new products; involves the examination of the organization’s
● current position of existing products on cash cost information in order to generate reliable
flow/product portfolio charts; and cost estimates for the probable costs of current
● estimated values for the company’s overall per- and new products and processes. These esti-

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EXHIBIT 11. MULTI-YEAR PRODUCT/PROFIT PLAN

Source: Ansari, et al., 1996: 137.

mates may include production costs, R&D costs, Process (Operational) Costing
physical distribution costs, and end-user costs. Process (operational) costing can be used to
The underlying objectives during this phase identify the cost drivers2 for each step of the
include the following: manufacturing process. Process costing makes
no attempt to account for the costs of individual
● determining what a new product’s costs would units or specific groups of products. Instead, all
be using existing product specifications and costs are accumulated by operations or process-
manufacturing processes; es. These costs are subsequently allocated from
● cost modeling; and processes to products on a systematic basis.
● analyzing internal costs.
Process costing directly considers the effects of
Several core tools and techniques typically used customer requirements and differentiates the
in this effort include: value-added costs likely to be incurred by serving
one group of customers versus another. The
● process (operational) costing; technique includes the impact of requirements
● component cost analysis; and on process characteristics such as capacity. The
● cost tables. result of this effort is an economic model of the
organization that clearly defines customer needs

2 Process cost drivers are process parameters that affect the efficiency or effectiveness of a process. Process cost drivers
affect process costs independently of any particular product mix.

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EXHIBIT 12. RATE MASTER LIST FOR PROCESS COSTS

Source: Monden, 1995: 256.

and the processes required to satisfy those processes provides the basis for developing cap-
needs. The model integrates marketing, opera- ital acquisition plans and finalizing product prof-
tional, and financial data to better understand itability analysis. Exhibit 12 provides an example
the total cost caused by a potential change to of a process-specific cost list that details prime
the product matrix. assumptions and current demand for parts of the
process affected by a new product.
An advantage of placing the costing emphasis on
processes is that the trade-offs between compet- Whether process costing is used to understand
ing products can be better identified. As the flow the overall impact of a new product on the exist-
of a new product is tracked through an existing ing plant or to estimate the cost implications of
facility, the target costing team can begin to iso- various design decisions, it plays a pivotal role in
late its impact on existing products to determine creating the probable cost estimate for current
where the new demand on resources will trigger and new products and processes.
constraints on overall throughput.
Component Cost Analysis
The creation of cost estimates for existing or new Component cost analysis decomposes the prod-

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STRATEGIC COST MANAGEMENT

EXHIBIT 13. COMPONENT COST ANALYSIS

Source: Ansari, et al., 1996: 137.

uct level target cost into the major component nent. Finally, it ensures that no outdated or soon
and parts categories. For example, a target cost to be out-of-production components are used.
list might be broken down by the following major
component categories and then by more detailed Exhibit 13 illustrates a component cost matrix.
parts categories: The cost column reveals the component cost,
and the availability column provides the last
● Breakdown of chassis functions: front axle, available date for the component before it
front brakes, rear brakes, etc.; becomes unavailable. The plus or minus entries
● Breakdown of body functions: white body highlight positive or negative relationships
metal, bumpers, window glass, etc.; and between the costs of components. A plus sign
● Breakdown of interior functions: seats, air con- indicates that as the cost of the component in
ditioning, interior panels, audio system, etc. row 1 is reduced, the cost of the component in
the column increases. For example, when the
A major component category may be further bro- cost of component C1 is reduced, the cost of
ken down into detailed part categories, for exam- component C2 increases, but the cost of compo-
ple, breakdown of seat systems: frame, slide nent C3 decreases.
rails, reclining mechanism, trim covers, etc.
Inputs and outputs required for effective compo-
Component cost analysis is particularly useful nent cost analysis include:
for assembly industries that purchase thou-
sands of components, parts, and subassem- Inputs:
blies. Component analysis has several important ● function-specific target cost outline;
uses. First, it identifies the expensive compo- ● actual costs of internal components in existing
nents of a product. Second, it focuses on the or similar products;
cost relationships between components. This ● current costs of purchased components in
helps to determine if decreasing the cost of one existing or similar products;
component increases the cost of another compo- ● component functional drawings and concept

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STRATEGIC COST MANAGEMENT

EXHIBIT 14. COMPONENT COST BREAKDOWN

Source: Ansari, Bell, Klammer, and Lawrence, 1997: TC-15.

manuals that show that the QFD objectives are other components by an equivalent amount.
being met;
● component-specific comparison of specifica- Cost Tables
tions for current and proposed models; Calculating the probable cost of current and new
● planned volume of products that will use com- products and processes depends, in large part,
mon components; and on reliable historical data. Cost tables enable
● component availability information. estimating costs for materials, parts, utilities,
and conversion. In essence, a cost table is a
Outputs: database that defines and depicts the cost
● component-specific target costs of in-house effects of using different materials, production
components; methods, and product designs.
● component-specific target costs of purchased
components; and Exhibit 15 shows one branch of a hypothetical
● component-specific target costs for the com- cost table. Additional branches would stem from
plete product. each of the cost driver alternatives under “drilling
activity.” In addition, similar branches would be
Exhibit 14 provides a breakdown of component prepared for “cutting” and “lathing.” At each
costs for a hypothetical coffeemaker. This infor- stage, the cost table would show unit product
mation can be used to identify and prioritize cost split into direct material, direct labor, and
cost-reduction efforts at the component level. production overhead.
Care must be taken to ensure that the sum of
the component-level target costs does not There are two general types of cost tables:
exceed the target cost of the product. Often an approximate cost tables and detailed cost
increase in the cost of one component requires tables. Approximate cost tables emphasize a
an exploration of ways to reduce the costs of small number of key variables that are known to

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STRATEGIC COST MANAGEMENT

EXHIBIT 15. COST TABLE STRUCTURE

Source: Yoshikawa, et al., 1996: F3-25.

have significant impacts on the final cost of a Cost tables are typically developed using both
product, such as the impact of different engine internal and external expertise from across
specifications on the cost to design and produce multiple functions, perspectives, and organiza-
a motorcycle. tions. Since upwards of 80 percent of a prod-
uct’s life-cycle cost is set before the product is
Relatedly, a detailed cost table includes the launched into production, the time and effort
relationship between a large number of vari- required to develop and maintain cost tables is
ables and their relevant costs. Typically devel- an essential investment in current and future
oped over many years, cost tables are used profitability.
from the original design throughout the life cycle
of the product. They are updated on an ongoing Combined with computer-aided design (CAD),
basis, serving as a critical decision-making aid cost tables can provide for real-time analysis of
in the design and ongoing management of a the cost implications for a proposed change in
product portfolio. product or component design or redesign.

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STRATEGIC COST MANAGEMENT

Finally, cost tables are often used to support formulas can be used to set a sales-price-based
“what if” (sensitivity) analysis at all stages of the target cost:
product life cycle.
Target cost = target sales price x
Toyota uses cost tables in five key production (1 – target return-on-sales ratio)
steps: machining, casting, body assembly, forg- or
ing, and general assembly. The cost tables Target cost = target sales price – target
detail the machine rates for each step of the operating profit.
production process. These rates include labor,
electricity, supplies, and depreciation costs. Relatedly, the target cost can also be calculated
The exact form of Toyota’s cost tables depends by subtracting the per-unit profit improvement
on the type of production step being analyzed; target from the estimated cost, then isolating
for example, for stamping, the cost table con- those costs.
tains the cost per stroke while for machinery it
contains the cost per machine hour. Toyota’s Having established the basic parameters for the
cost tables are highly detailed, and, in most target costing system and identified the appropri-
cases, each production line has its own cost ate level of execution at which it should be car-
table. ried out, attention turns to establishing specific
cost and performance targets. A useful tool that
Establishing the Target Cost can be used in this step is benchmarking.
Once the target market price and target profit
have been established, the target cost can be Benchmarking
calculated. The target cost reflects the relative One of the most important aspects of creating a
competitive position of the organization. It also target cost for a product or service is guarantee-
represents the cost at which the product must ing, at both the total and component level, that
be manufactured if it is to achieve the target functionality and costs are competitively estab-
profit margin when sold. The target cost acts as lished. Benchmarking, which compares costs of
a signal to all involved in the target costing specific products, activities, and outcomes to
process as to the magnitude of the cost reduc- those of competitive or best-practice companies,
tion objective that eventually must be achieved. provides valuable input to target costing in this
The established target cost should be attain- effort. Issues that can be addressed through
able, but only with considerable effort. benchmarking studies include:
Objectives that drive the achievement of these
goals include: ● identification of the best practice in completing
core and support activities for the product or
● setting continuous improvement targets; service;
● measuring performance; and ● establishment of objective cost targets and
● communicating cost requirements. performance metrics for component suppliers
and internal processes;
Target costs can be calculated using the target ● definition of quality and delivery parameters
return-on-sales ratio or a compilation of estimat- for similar products, processes, or compo-
ed costs. In the former case, one of two primary nents across comparable industries;

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STRATEGIC COST MANAGEMENT

EXHIBIT 16. BENCHMARKING STEPS

Source: IMA, Effective Benchmarking.

● identification of process improvements that into several steps by the leading practitioners.
can provide quantum improvements in overall They all use an integrated approach to bench-
cost and profit performance; marking reflected in the following five general
● development of innovative analysis and design steps: planning, data gathering, analysis and
techniques based on benchmarking site visits integration, implementation/execution, and re-
and case studies; and calibration, as illustrated in Exhibit 16.
● creation of an ongoing network of organiza-
tions capable of supporting current and future Organizations that are at a significant competitive
improvements and target costing initiatives. disadvantage will benefit most from estimating
benchmark costs and calculating the difference
The benchmarking process has been formalized between those costs and their target cost. If the

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STRATEGIC COST MANAGEMENT

disadvantage is significant, it might not be possi- step in attaining target costs. Using the total,
ble to reach the benchmark costs in a single gen- fully absorbed costs as the baseline, current
eration of product design. Such organizations will costs represent the “as-is” estimate of the cost
have to adopt a multi-release strategy of product of producing the product or providing the service.
design, setting ever more aggressive cost targets
for each release. The narrowing gap between the The resulting cost gap is decomposed into two
benchmark and the target cost would demon- primary parts: life-cycle costs and value-chain
strate the achievement of competitive parity. costs. Life-cycle decompositions emphasize the
total product cost of the birth-to-death activities
Attaining the Target Cost performed in research, manufacturing, distribu-
Once the target cost has been established, the tion, service, general support, and disposal.
goal is to develop a new product concept that Conversely, value-chain analysis examines costs
attains the target cost while meeting all cus- based on whether they are incurred and con-
tomer requirements. The process of attaining the trolled by the organization or by one of its value-
target cost is supported by various methods that chain partners (e.g., suppliers, dealers, or dis-
reveal cost-reduction potentials and show ways posers). As noted by Ansari, “The two break-
to transform those potentials into design alter- downs take the same total cost but provide two
natives. Key objectives at this stage of the target different kaleidoscopic views of the product
costing effort include: cost. Each helps to highlight where cost reduc-
tion efforts need to be focused.” Exhibit 17 pro-
● optimize the relationship between materials, vides a detailed illustration of the cost gap
parts, and manufacturing processes; analysis effort.
● minimize costs;
● focus design efforts on market-driven variables Designing Costs Out of the Product
for quality and cost of ownership; Reducing costs through the product design stage
● link product development with customer is the most critical step in attaining target costs.
desires and to achieving a sustainable com- The key to achieving desired reductions lies in
petitive advantage; the answer to one specific question: How does
● link the product development process so that the design of this product affect all costs associ-
it assures product quality; and ated with the product from its inception to its final
● estimate the cost prior to implementation. disposal? Identifying all costs, whether incurred
in distribution, selling, warehousing, service,
Turning the allowable cost target into an achiev- support, or recycling, is essential as all of these
able cost requires three primary steps: (1) com- cost elements, which are generated by the differ-
pute the cost gap; (2) design costs out of the ent functions, are affected by the design chosen.
product; and (3) release the design to manufac-
turing and undertake continuous improvement. For instance, the weight and control panel are two
elements of a convection oven that are affected
Computing the Cost Gap by the product’s design. A heavy oven will
Calculating the difference between the target increase loading, transportation, and installation
cost (calculated from the target price and profit costs if two people are required to perform these
margin) and current cost estimates is the first activities. Relatedly, an elaborate control panel

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STRATEGIC COST MANAGEMENT

EXHIBIT 17. COMPUTING THE COST GAP

Source: Ansari, et al., 1996: 146.

will increase the time required to explain the Achieving cost reductions before production
product’s use to customers, as well as increasing begins is aided by the use of two specific tools
the potential for product support and repair and techniques: (1) design for manufacture and
costs, due to failures in electronic and mechani- assembly and (2) value engineering.
cal components. Finally, the materials used may
ultimately pose an environmental hazard that has Design for Manufacture and Assembly
to be handled at the point of disposal. All these (DFMA)
factors add to the product’s cost with little or no DFMA is an approach to product design that can
improvement in customer satisfaction. improve an organization’s ability to compete
based on its manufacturing capability.
Releasing Design to Manufacturing and Specifically, DFMA focuses on reducing costs by
Undertaking Continuous Improvement making products easier to manufacture while
The final stage in attaining the target cost is to holding functionality at specified levels. DFMA
continue to make product and process improve- guides development of the detailed product
ments that will reduce costs beyond the point design, ensuring that at every stage of the
where it is possible through design alone. It assembly and manufacture process minimal
includes eliminating waste (scrap, rework, etc.), cost and waste elimination targets will be
improving production yield (i.e., getting more pro- reached. The DFMA methodology is based on
duction from raw materials), and other such five basic principles:
measures.
● Reduce the number of parts by combining

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STRATEGIC COST MANAGEMENT

parts (i.e., multifunction parts). Seek to com- ● through disassembly, reduction of life-cycle
bine parts unless separate parts are neces- costs for maintaining the product in the field;
sary because they must be of a different mate- ● reduction of potential defects and related
rial, move relative to each other, or are neces- engineering-change notices to correct design
sary to ease assembly or disassembly. or assembly problems;
● Assemble from the top down, rather than from ● increase in assembly efficiency and effective-
the side or bottom. ness; and
● Design symmetry into parts so that they may ● improve throughput and time-to-market.
be assembled in many orientations. If this is
not possible, be sure they are very symmetri- DFMA methodology has been successfully applied
cal so they can be easily oriented and fed. at many organizations, including several different
● Design parts to be easily handled and insert- development programs within the Boeing Company.
ed without restricted access. In each case, cross-functional teams were estab-
● Use flexible manufacturing processes wherev- lished to develop a new product that either
er possible (e.g., powder metal processing, enhanced performance and/or reduced cost.
injection molding, stamping). These specific examples include 737 flight deck air
valve, 737 windshield replacement, and 737/757
Without DFMA, the projected benefits of a new passenger cabin sidewall panel assemblies. The
product design may not be attained. For teams applied the DFMA process in developing
instance, at an organization making a variety of their new products. Exhibit 18 shows the top level
mechanical counters, a product was designed results from these three different programs.
that required extreme dexterity to manufacture
because multiple wires had to be encapsulated Value Engineering (VE)
in a snap-together casing. Once the casing was VE is used by organizations to increase product
assembled, it could not be disassembled (it functionality and quality while at the same time
became scrap). As the product rolled out to man- reducing costs. The scope of VE includes design
ufacturing, it was found that only one person costs reduction, process improvements, and
could produce it reliably. No one else in the plant working with suppliers. The output of VE is a
could consistently accomplish the task of getting series of improvement plans that raise the value
all the wires into the casing before its closure. of the target product. Emphasizing functionality
The entire production of this item was limited by and meeting customer requirements within the
poor execution of a good design concept—a fail- allowable cost parameters, VE goes beyond the
ure to apply DFMA. particular styles or configurations of current
products to consider the functions that lie at the
DFMA enables the attainment of cost targets by heart of the product in order to come up with
finding unique, low-cost, yet robust ways to trans- innovative ways to achieve desired functionality
form product concepts into reality. The benefits with less cost or effort.
it can provide include:
As suggested by Exhibit 19, VE studies the vari-
● elimination of excess parts; ous requirements of functionality and quality that
● active inclusion or development of common occur during the entire life cycle of a product.
parts for a wide range of applications; These include:

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STRATEGIC COST MANAGEMENT

EXHIBIT 18. BOEING DFMA APPLICATION RESULTS SUMMARY

Source: Behun, 1995: 101.

● user requirements: use-objectives, use- engineering the product beyond what will meet a
conditions and environments, performance customer’s needs.
features, reliability, safety, durability, design,
shape, color, etc.; Isuzu is a significant user of VE. The develop-
● sales requirements: selling points, competitive ment of their NAVI-5 transmission system, which
performance features, competitive pricing, and combines the higher fuel efficiency and perfor-
related factors, mance of a manual transmission with the con-
● design-related requirements: performance lev- venience of an automatic transmission, used VE
els, added-function levels, etc.; concepts. Specifically, VE was used to develop a
● manufacturing-related requirements: processing Gemini (ceramic) heater that would reduce the
technologies, manufacturing processes, and relat- time it took to warm up a car’s interior by focus-
ed labor hours, materials, and purchased parts; ing early heat from the engine through a second-
● distribution-related requirements: packaging, ary heating system that directed warm air at
loading, storage, transportation, etc.; occupants’ feet until the engine was warm
● cost-related requirements: management of enough to support the traditional heating sys-
progress toward achieving target costs; and tem. Also, VE was used to develop a gear lever
● legal and regulatory requirements: patents and that would fold down while the vehicle was sta-
utility models, environmental protection laws, tionary but that would not collapse while the
industry regulations, government guidelines, vehicle was in motion.
and related factors.
Having made the improvements required to
Exhibit 20 illustrates an example of VE cost- transform the target costs into achievable costs,
cutting ideas that focus on reducing the number attention can now turn to achieving continuous
of parts, simplifying the assembly, and not over- improvements on the plant floor.

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STRATEGIC COST MANAGEMENT

EXHIBIT 19. VALUE ENGINEERING (VE) FRAMEWORK

Source: Monden, 1995: 220.

Pursuing Cost Reductions Once product- and component-level costs. The objec-
Production Has Started tive at this stage is to pursue cost reductions
The start of production signals the beginning of relentlessly at every stage of manufacturing to
the cost maintenance phase, which emphasizes close any remaining gaps between targeted and
the stabilization of or continuous improvement in actual profits.

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STRATEGIC COST MANAGEMENT

EXHIBIT 20. VALUE ENGINEERING (VE) IDEAS TO REDUCE COSTS

Source: Ansari, Bell, Klammer, Lawrence, 1997: TC-20.

Organizations that have successfully implement- costing tools because they focus attention on
ed target costing, such as Texas Instruments how product design leads to the consumption of
and Toyota, note the importance of cost informa- various activities and, therefore, increases over-
tion in cost reduction initiatives. Key objectives all costs. For instance, material handling is relat-
at this stage include: ed to the number of unique parts purchased,
which is a function of design complexity.
● providing improved product cost information;
● providing improved performance monitoring; ABC and ABM can also be used to increase the
and understanding of cost items such as manufactur-
● improving understanding of the true cost ing overhead, marketing, distribution, service
structure. and support, and general business overhead.
Where ABC and ABM provide inputs to a decision
A useful tool for this cost reduction effort is technique for improving the use of current and
activity-based costing/activity-based manage- anticipated resources, target costing applies this
ment (ABC/ABM). information to change the nature and amount of
currently available resources.
ABC and ABM
Achieving cost reduction objectives requires Exhibit 21 details the relationship between ABC,
information that identifies the causes of current ABM, and target costing. The interaction of
cost and the potential impact of attacking these reductions in direct costs that remain the pri-
cost drivers. ABC and ABM are valuable target mary focus of target costing and the cuts in, or

27
STRATEGIC COST MANAGEMENT

EXHIBIT 21. RELATIONSHIPS BETWEEN ABC, ABM, AND TARGET COSTING

Source: Sakurai, 1996: 124.

improvement of, indirect costs and activities which reflect trade-offs made by the organiza-
under ABC and ABM creates an ongoing basis for tion to hit cost targets;
improvement and development of a competitive ● sensitivity analysis, which incorporates the
cost and profit profile for existing and new underlying behavior of cost and the cost of idle
products. or unused capacity to increase the accuracy of
target cost estimates; and
At almost every turn, target costing can utilize ● creation of cross-functional, process-oriented
information available in ABC and ABM systems costing tools that support brainstorming, con-
to identify current actual costs, analyze the caus- current engineering, and kaizen costing
es of that cost, and find ways to reduce overall efforts.
indirect costs by changing the ways products are
designed, developed, manufactured, and sold. ABC and ABM are important tools that support
Using ABC and ABM in the target costing target costing at Caterpillar. Both tools are
process provides the following benefits: applied on a prospective basis to estimate prod-
uct and process costs. During the early stages of
● quantification of costs, both value-added and product development, ABC is used to estimate
nonvalue-added, by activity, cost element, com- product cost at a general level. This is useful for
ponent, and product; preliminary evaluation of product feasibility. As
● identification and estimation of the costs to product and process definition become more
meet specific customer functionality and qual- precise, predictive ABM process cost models are
ity requirements; applied to estimate the costs of particular func-
● analysis of the costs of complexity; tions and components using particular process-
● measurement of the impact of QFD, DFMA, and es. This has been particularly valuable to engi-
VE initiatives on current and projected costs; neers as they work to reduce product and
● enhanced ability to take action to reduce over- process cost, improve utilization of current
head costs; machines and equipment, and eliminate waste
● support of cost of quality and related analysis, and process variation.

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STRATEGIC COST MANAGEMENT

VI. CONCLUSION Cooper, R. “Nissan Motor Company, Ltd.: Target


Target costing seeks to anticipate costs before Costing System.” Harvard Business School
they are incurred, continually improve product Case #9-194-040, 1994.
and process designs, externally focus the orga- Dutton, J. John, and Mark Ferguson. “Target
nization on customer requirements and competi- Costing at Texas Instruments.” Journal of
tive threats, and systematically link an organiza- Cost Management, Fall 1996, pp. 33-38.
tion to its suppliers, dealers, customers, and Fisher, Joseph. “Implementing Target Costing.”
recyclers in a cohesive, integrated profit and cost Journal of Cost Management, Summer 1995,
planning system. pp. 50-59.
Guinta, L.R., and N.C. Praizler. The QFD Book.
Target costing is the means to achieve competi- New York: AMACOM Books, 1993.
tive advantage through active management of Institute of Management Accountants.
the unavoidable trade-offs and constraints faced Statement on Management Accounting,
by any organization providing goods and services Implementing Activity-Based Management:
to the market. Emphasizing proactive, rather Avoiding the Pitfalls. Montvale, NJ: May
than reactive, cost containment, target costing 1998.
ensures short- and long-term profitability and IMA. Statement on Management Accounting,
success by putting customer needs and function- Implementing Target Costing. Montvale, NJ:
ality first, using them to drive the design, devel- November 1998.
opment, manufacture, and provision of products. Monden, Y. Cost Reduction Systems. Portland,
Target costing redefines the competitive playing OR: Productivity Press, 1995.
field—a challenge that cannot be avoided, only Sakurai, M. Integrated Cost Management.
enjoined. Portland, OR: Productivity Press, 1996.
Tanka Takao. “Target Costing at Toyota.” Journal
VII. BIBLIOGRAPHY of Cost Management, Spring 1993, pp. 4-11.
Ansari, S., J. Bell, T. Klammer, and C. Lawrence. Terninko, J. Step-by-Step QFD: Customer-Driven
“Target Costing” in Management Accounting: Product Design. Boca Raton, FL: St. Lucie
A Strategic Focus. Homewood, IL: Irwin, Press, 1997.
1997. Yoshikawa, R., J. Innes, and F. Mitchell.
Ansari, et al. Target Costing—The Next Frontier in “Japanese Cost Management Practices.”
Strategic Cost Management. Homewood, IL: Handbook of Cost Management. New York:
Irwin and Bedford, TX: Consortium for Warren, Gorham and Lamont, 1996: p. F-3.
Advanced Manufacturing-International (CAM- Yutaka, Kato, Germain Boer, and Chee W. Chow.
I), 1996. “Target Costing: An Integrated Management
Behun, J.R., ed. “Design for Manufacturability.” Process.” Journal of Cost Management,
Design Engineering, Vol. 81. New York: The Spring 1995, pp. 39-51.
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1995.
Cooper, R., and R. Slagmulder. Target Costing and
Value Engineering. Portland, OR: Productivity
Press and Montvale, NJ: Institute of
Management Accountants, 1997.

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