David Christensen, plant manager, was given the charge to produce 120,000 bolts used in the…

David Christensen, plant manager, was given the charge to produce 120,000 bolts used in the manufacture of small twin-engine aircraft. Directed by his divisionalmanager to give the bolt production priority over other jobs, he had two weeks to produce the units. Meeting the delivery date was crucial for the renewal of a major contract with a large airplane manufacturer. Each bolt requires 20 minutes of directlabor and five ounces of metal. After producing a batch of bolts, each bolt is subjected to a stress test. Those that pass are placed in a carton, which is stamped“Inspected by inspector no. ____” (the inspector’s identification number is inserted).Defective units are discarded, having no salvage value. Because of the nature of theprocess, rework is not possible.
At the end of the first week, the plant had produced 60,000 acceptable units andused 24,000 direct labor hours—4,000 hours more than the standard allowed. Furthermore, a total of 65,000 bolts had been produced, and 5,000 had been rejected,creating an unfavorable materials usage variance of 25,000 ounces. David knew thata performance report would be prepared when the 120,000 bolts were completed.This report would compare the labor and materials used with that allowed. Any variance in excess of 5 percent of the standard would be investigated. David expected the same or worse performance for the coming week and was worried about a poor performance rating for himself. Accordingly, at the beginning of the second week,David moved his inspectors to the production line (all inspectors had productionexperience). However, for reporting purposes, the production hours provided by inspectors would not be counted as part of direct labor. They would still appear as aseparate budget item on the performance report. Additionally, David instructed the inspectors to pack the completed bolts in the cartons and stamp them as inspected.One inspector objected; David reassigned the inspector temporarily to materials handling and gave an inspection stamp with a fabricated identification number to aline worker who was willing to stamp the cartons of bolts as inspected.
Required1. Explain why David stopped inspections on the bolts and reassigned inspectors to production and materials handling. Discuss the ethical ramifications of thisdecision.2. What features in the functional-based responsibility accounting system provided the incentive(s) for David to take the actions described? Would an activity-basedor strategic-based responsibility accounting system have provided incentives that discourage this kind of behavior? Explain.3. What likely effect would David’s actions have on the quality of the bolts? Was the decision justified by the need to obtain a renewal of the contract, particularly if the plant returns to a normal inspection routine after the rush order iscompleted? Do you have any suggestions about the quality approach taken bythis company? Explain why activity-based responsibility accounting might playa useful role in this setting

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