Reference no: EM132614765

Assume you are the management accountant for the Foleo Group. James and Leon have called you and the CFO into a meeting to discuss concerns they have with the number of SliFones that are being returned by customers under warranty. They have pulled some numbers from the accounting system and elsewhere regarding not only the warranty costs, but also other expenses associated with the quality of the phones for the 2016 year. The directors have handed you the below costs and asked you to look into why faulty SliFones are being returned by customers even though Foleo Fones is spending so much on the quality of their product.

Quality Activity           Cost of Quality Activity

P/A/I/E

Inspection of components purchased from suppliers              $17,000

Testing phones during production processes                    $25,000

Cost of reworking faulty phones                                       $24,500

Quality Assurance testing before delivery of phones            $11,700

Cost of repairing & replacing faulty phones returned under warranty    $78,300

Cost of servicing customers' quality complaints                               $66,900

Cost of scrapped phones during production                               $11,300

Service callout costs to customer sites to fix phones                 $37,600

Quality training for production staff                                     $5,000

Legal fees defending safety claims against the SliFone batteries       $250,000

Cost of recalling SliFones with faulty batteries                               $174,500

Lost contribution margin on future sales due to quality issues            $95,000

Production downtime due to suppliers' poor quality components            $67,500

Depreciation on testing equipment                                                $23,000

Maintenance on production equipment                                          $1,300

Freight costs to & from customers for phone repairs                          $3,500

TOTAL QUALITY COSTS                                                              $892,100

Question (a) Classify each of the quality costs as Prevention (P), Appraisal (A), Internal (I) or External (E) Failure costs.

Question (b) Prepare Cost of Quality Report, including the percentage of total cost for each category.

Question (c) Prepare written report for the Directors that explains and analyses the Cost of Quality Report you have just prepared. In your report to James and Leon, you must also include a recommendation on how to improve the overall quality of the SliFone.