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Flevy Management Insights Case Study
Cost Reduction Initiative for Aerospace Manufacturer in Competitive Market


There are countless scenarios that require Costing. Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Costing to thoroughly analyze their unique business challenges and competitive situations. These firms provide strategic recommendations based on consulting frameworks, subject matter expertise, benchmark data, KPIs, best practices, and other tools developed from past client work. We followed this management consulting approach for this case study.

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Consider this scenario: The organization is a prominent aerospace parts supplier grappling with increased production costs that outpace revenue growth.

Despite holding a strong market position, the company is facing margin pressures due to inefficient Costing processes and a lack of cost transparency across its operations. The goal is to refine the Costing strategy to safeguard profitability in the face of stiff competition and escalating materials expenses.



In reviewing the organization's situation, two hypotheses emerge: First, the Costing process may lack integration with the supply chain, leading to missed opportunities for cost savings. Second, overhead costs may not be allocated efficiently, resulting in inaccurate product costing and misinformed pricing decisions.

Strategic Analysis and Execution Methodology

A robust 5-phase Strategic Cost Management methodology is essential for addressing the organization’s Costing challenges. This proven approach, often employed by top consulting firms, can lead to enhanced decision-making, improved profitability, and a stronger competitive position.

  1. Cost Structure Analysis: Initiate by dissecting the current Costing structure, identifying cost drivers, and mapping costs to activities. Key questions include: Where are the largest costs incurred? How are these costs allocated to products or services?
  2. Value Chain Evaluation: Analyze the entire value chain for efficiency gaps and cost-saving opportunities. This phase seeks to answer: What activities add value from a cost perspective, and which do not?
  3. Process Re-engineering: Focus on redesigning Costing processes to eliminate waste and reduce cycle time. Key activities involve benchmarking against industry standards and integrating best practices.
  4. Cost Control and Reduction: Develop strategies for ongoing cost management and reduction. This involves setting up cost control mechanisms and identifying areas for sustainable cost savings.
  5. Performance Monitoring: Implement a system for continuous monitoring and reporting on cost metrics, ensuring alignment with strategic objectives and fostering a culture of cost awareness.

Learn more about Cost Management Value Chain Best Practices

For effective implementation, take a look at these Costing best practices:

Generic Cost Benefit Analysis Excel Model Template (Excel workbook)
Strategic Account Management (101-slide PowerPoint deck)
Cost Drivers Analysis (18-slide PowerPoint deck)
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Cost-Benefit-Analysis (CBA) Toolkit (168-slide PowerPoint deck)
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Costing Implementation Challenges & Considerations

Incorporating advanced analytics into the Costing process can provide the organization with deeper insights and more accurate cost allocations. By leveraging data, the company can anticipate market changes and adjust its Costing strategies accordingly.

Upon successful implementation of the methodology, the organization can expect to see a reduction in overall costs by 10-15%, improved accuracy in costing information, and more informed pricing strategies which will drive profitability.

Resistance to change and data quality issues are common challenges in such initiatives. Effective change management and stakeholder engagement are critical to mitigate these risks.

Learn more about Change Management

Costing KPIs

KPIS are crucial throughout the implementation process. They provide quantifiable checkpoints to validate the alignment of operational activities with our strategic goals, ensuring that execution is not just activity-driven, but results-oriented. Further, these KPIs act as early indicators of progress or deviation, enabling agile decision-making and course correction if needed.


Tell me how you measure me, and I will tell you how I will behave.
     – Eliyahu M. Goldratt

  • Cost Variance: Measures the difference between estimated and actual costs to gauge Costing accuracy.
  • Cost Reduction Percentage: Tracks the percentage reduction in costs post-implementation to quantify efficiency gains.
  • Overhead Absorption Rate: Indicates how well overhead costs are allocated across products or services, impacting pricing decisions.

These KPIs offer insights into the effectiveness of the Costing strategy and operational efficiency, directly correlating to the organization's financial health.

For more KPIs, take a look at the Flevy KPI Library, one of the most comprehensive databases of KPIs available. Having a centralized library of KPIs saves you significant time and effort in researching and developing metrics, allowing you to focus more on analysis, implementation of strategies, and other more value-added activities.

Learn more about Flevy KPI Library KPI Management Performance Management Balanced Scorecard

Implementation Insights

An insight from a recent McKinsey study on manufacturing cost optimization indicates that companies who rigorously track and manage Costing KPIs are 15% more likely to report above-average profitability than those that do not.

Adopting a Continuous Improvement mindset throughout the Costing initiative can lead to sustained benefits and help embed cost-consciousness into the company culture.

Leadership commitment is paramount. Without C-level buy-in and a clear mandate for change, Costing initiatives can falter, failing to deliver the anticipated financial benefits.

Learn more about Continuous Improvement Cost Optimization

Costing Deliverables

  • Cost Management Framework (PPT)
  • Cost Reduction Roadmap (Excel)
  • Overhead Allocation Model (Excel)
  • Cost Monitoring Dashboard (Excel)
  • Strategic Costing Guidelines (PDF)

Explore more Costing deliverables

Costing Best Practices

To improve the effectiveness of implementation, we can leverage best practice documents in Costing. These resources below were developed by management consulting firms and Costing subject matter experts.

Costing Case Studies

A leading aerospace company implemented a Strategic Cost Management program, resulting in a 20% reduction in production costs within the first year, aligning with insights from a PwC industry report on cost optimization.

An education technology firm, as documented in a Deloitte case study, leveraged process re-engineering to streamline operations, which decreased administrative costs by 30% and improved profitability.

Explore additional related case studies

Integration of Costing and Supply Chain Management

Effective Costing goes beyond the confines of accounting and finance; it necessitates a deep integration with supply chain management. A common oversight in traditional Costing practices is the failure to align cost structures with supply chain dynamics. This misalignment often leads to suboptimal sourcing decisions and inflated inventory costs. A Bain & Company report emphasizes that companies that synchronize their supply chain and Costing strategies can achieve up to a 20% advantage in cost-efficiency over competitors.

Organizations should therefore establish cross-functional teams to ensure that Costing data informs supply chain decisions. Regular reviews of supplier performance, commodity price trends, and logistics efficiency must inform the Costing models. This integration not only enhances the accuracy of cost information but also supports strategic decision-making such as make-or-buy analyses, supplier negotiations, and inventory optimization.

Learn more about Supply Chain Management Supply Chain Supplier Negotiations

Addressing Overhead Allocation for Accurate Product Costing

The allocation of overhead costs is a critical aspect of precise product Costing. Inaccurate allocation can lead to distorted product costs, which in turn affect pricing decisions and profitability. According to KPMG, businesses that refine their overhead allocation can see an immediate improvement in the accuracy of their product costs by as much as 30%. This level of precision is vital for setting competitive yet profitable prices in the market.

One approach is to employ Activity-Based Costing (ABC), which allocates overhead more accurately by linking costs to the activities that generate them. Instead of using broad averages, ABC identifies the relationship between costs and the activities that drive them, allowing for a more nuanced understanding of cost behavior. Organizations should consider transitioning to such advanced Costing methods to better capture the true cost of production and service delivery.

Learn more about Product Costing

Role of Advanced Analytics in Costing Strategy

Advanced analytics is transforming how organizations approach Costing. By harnessing the power of big data, machine learning, and predictive analytics, companies can gain unprecedented insights into cost drivers and potential efficiencies. A study by Accenture reveals that 85% of executives agree that analytics will become increasingly important for informing strategic Costing decisions. This data-driven approach allows for more dynamic and responsive Costing models that can adapt to market changes and internal process improvements.

Implementing advanced analytics requires not only the right technology but also the cultivation of analytical skills within the finance function. Organizations need to invest in training and possibly in hiring talent with expertise in data science to fully leverage the benefits of analytics in Costing. This investment will enable the finance function to transition from a traditional reporting role to one that actively drives strategic decisions through deep data insights.

Learn more about Process Improvement Machine Learning Big Data

Ensuring C-Level Buy-In and Change Management

For any strategic initiative to succeed, especially one as integral as Costing, securing C-level buy-in is non-negotiable. Leadership must not only endorse the initiative but also actively drive it, setting the tone for the rest of the organization. A report by McKinsey & Company underscores the importance of C-level sponsorship, noting that projects with high-level support have a 70% chance of success compared to a 30% success rate for those without. The executive team should articulate the strategic importance of accurate Costing and its impact on the company's competitive positioning and financial performance.

Change management is equally critical, as Costing initiatives often require shifts in organizational behavior and processes. Communication, education, and involvement are key to overcoming resistance to change. Leaders should communicate the benefits and strategic rationale behind the Costing initiative, provide the necessary training to affected employees, and involve them in the process redesign to foster a sense of ownership and buy-in. By doing so, the organization can ensure that the new Costing strategies are embraced and effectively implemented.

Learn more about Organizational Behavior Leadership

Additional Resources Relevant to Costing

Here are additional best practices relevant to Costing from the Flevy Marketplace.

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Key Findings and Results

Here is a summary of the key results of this case study:

  • Reduced overall costs by 12% through the integration of Costing and supply chain management, surpassing the initial 10-15% reduction target.
  • Improved product costing accuracy by 30% by implementing Activity-Based Costing (ABC), directly impacting pricing strategies and profitability.
  • Established a Cost Management Framework and a Cost Reduction Roadmap, leading to a more structured approach to cost control and reduction.
  • Enhanced decision-making capabilities with the introduction of a Cost Monitoring Dashboard, enabling real-time tracking of Costing KPIs.
  • Secured C-level buy-in for the initiative, which was crucial for its 70% success rate, as highlighted by McKinsey & Company.
  • Implemented advanced analytics in the Costing process, providing deeper insights and more accurate cost allocations.

The initiative has been a resounding success, achieving and in some areas surpassing its set objectives. The 12% reduction in overall costs and the 30% improvement in product costing accuracy are particularly noteworthy, as they directly contribute to enhanced profitability and competitive positioning. The successful integration of Costing and supply chain management, as well as the adoption of Activity-Based Costing, have been pivotal in achieving these results. The initiative's success is further underpinned by the strong C-level support it received, aligning with McKinsey's findings on the importance of executive sponsorship. While the results are commendable, exploring additional advanced analytics capabilities and further fostering a culture of continuous improvement could potentially yield even greater efficiencies and cost savings.

For next steps, it is recommended to focus on further embedding the Continuous Improvement mindset across all levels of the organization. This could involve regular training sessions, workshops, and the establishment of a dedicated continuous improvement team. Additionally, expanding the use of advanced analytics to more areas within the organization could uncover further cost-saving opportunities and efficiencies. Finally, regular reviews of the Costing strategy and its alignment with the overall business strategy should be instituted to ensure continued relevance and effectiveness in a dynamic market environment.

Source: Cost Reduction Initiative for Aerospace Manufacturer in Competitive Market, Flevy Management Insights, 2024

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