2. Consideration of Variable and Fixed Costs
Kaizen costing is applied by value analysis. In kaizen costing kaizen targets are set for all plants and manufacturing processes. Cost of raw material is significant for cost reduction and it can be reduced by better manufacturing processes. Purchased tools or items for product are generally not allocated cost reduction targets for cost reduction point of view these can be purchased at a low price with suppliers’ negotiation. Other variable cost is mainly centre of attention for cost reduction in kaizen costing which are reduced through value analysis. Fixed costs are not part of cost reduction. The cost reduction target rates are generally fixed for each product component and department only small changes are made in these rates (Monden & Lee, 1993). The company wide cost reduction target amount is allocated to each plant and these assigned target cost reduction rates in each plant may be higher or lower than the company wide rate (Monden & Lee, 1993). During decomposition of cost reduction targets different meetings are held at different levels of each plant for best allocation of targets
(Monden & Lee, 1993). The total company wide target cost reduction target is actually decomposed among all cost elements. The kaizen cost improvement activities are very specific for every department in the company. Monden & Lee (1993) described those Japanese automobile companies like Daihatsu Motor Corporation prepares following six plans for cost reduction for the application of kaizen costing.