TEM Journal. Volume 9, Issue 2, Pages 763‐769, ISSN 2217‐8309, DOI: 10.18421/TEM92-45, May 2020.

Using Throughput for Management and Performance Assessment: Constraint Theory Approach

Hatem Karim Kadhim, Karar Jasim Najm, Hayder Neamah Kadhim

Department of Accounting, Faculty of Administration and Economics, University of Kufa, Najaf, Iraq

Abstract – The paper aims to use throughput This approach provides management as an approach for developing cost information in line with the current accounting systems in the modern manufacturing environment and limited resources to improve the environment to evaluate the organization performance. operational performance of origination. It reduces The sample consists of (60) persons in organization for throughput time, operating and inventory. The examining the hypotheses. The findings show that information provided by throughput accounting helps beginning of the transition period is in the mid- in measuring costs and evaluate the efficiency and seventies from the last century in the area of effectiveness of performance in the organization. This and administrative science inside Goldratt's writings. approach supports planning and control processes to In the early 1990s, Throughput Accounting emerged maximize throughput and reduce inventory levels. The as a result of the development of the Theory of use of Throughput Accounting under the Theory of Constraint. Management needs knowledge in the Constraints leads to finding solutions to bottlenecks modern manufacturing environment. Throughput that affect the efficiency and effectiveness of Accounting is one of the modern approaches to cost performance. measurement and performance assessment. This Keywords – Throughput Accounting, Theory of approach provides a comprehensive vision of the Constraints, origination’s performance. organization and encourages consistency between the different departments and activities of the 1. Introduction organization [1]. The importance of research stems from the role of Throughput Accounting in Recently, a cost accounting system has been addressing the negative effects of misuse of required to adapt to changes in the contemporary resources in restricted operations, which leads to a environment in order to manage scarce resources, decrease in productivity and quality of output. bottlenecks and production constraints. Throughput Throughput Accounting is one of the uses the principle of constraints as an accounting methods that contributes to the provision introduction to the implementation of the cost of information, cost measurement and performance accounting system. assessment of the organization. The research issue is that many of the companies in Iraq are suffering from DOI: 10.18421/TEM92-45 issues related to the constraints faced during the https://doi.org/10.18421/TEM92-45 production process. The problems impede the Corresponding author: Karar Jasim Najm, continuous flow of production. These organizations Department of Accounting, Faculty of Administration and seek to raise the level of performance and remain in Economics, University of Kufa, Najaf, Iraq. the labor market. This strategy leads to rapid changes Email: [email protected] in the level of quality management, cost reduction, production efficiency and maximization of Received: 08 February 2020. productivity. The presence of these constraints Revised: 10 May 2020. restricts the efficiency of the organizations that have Accepted: 17 May 2020. contributed to the use of Throughput Accounting to Published: 27 May 2020. control the constraints and enhance the operating © 2020 Hatem Karim Kadhim, Karar Jasim performance of the organizations. Najm & Hayder Neamah Kadhim; published by UIKTEN. This work is licensed under the Creative Commons 2. Literature Review Attribution‐NonCommercial‐NoDerivs 4.0 License. (TOC) originated as an The article is published with Open Access at effective management theory that offers practical www.temjournal.com solutions to various complex problems, including the

TEM Journal – Volume 9 / Number 2 / 2020. 763 TEM Journal. Volume 9, Issue 2, Pages 763‐769, ISSN 2217‐8309, DOI: 10.18421/TEM92‐45, May 2020. problem of product mixing. Researchers have integrated system consisting of a set from principles, demonstrated the superiority of various methods of concepts and tools that help organizations to identify improvement over events based on the table of and address the constraints and bottlenecks to contents in the "fixed" product mix issue. achieve their goals and enhance their profits. Nonetheless, the content table could not be According to [14], [15], [16], there are many benefits interpreted as a whole, i.e. considering the effect of for the Theory of Constraints that can be summarized resource and comment loop dependence, and, most as the following: significantly, statistical variations occur in any . productivity increases to achieve the highest complex work environment [2]. In this context, [3] throughput as well as reduce time and operating attempts to implement each of the Activity-based costs. Costing (ABC) to determine and allocate costs . TOC helps to attain the continuous improvement accurately and implement Theory of Constraints of the system performance in organizations. (TOC) with the help of Microsoft Excel. [4] . Increasing the flow rates by solving the examines applying the TOC Thinking Process: A fundamental constraints and meet the actual case study in the government sector. they show the demand for goods or services. importance of the thinking approach in addressing . TOC reduces the work in process inventory by constraints in the water maintenance department in removing the bottlenecks facing the production water services organizations and work to build an process to reduce the accumulation of inventory environment free of errors and problems by between activities. identifying constraints and addressing them through . It is a tool that helps to work in a team spirit in the components of the Thinking approach. [5] uses different areas of the organization which is the Theory of Constraints under the ABC approach to reflected positively on the identification and allocate costs accurately and identify obstacles in the removal of constraints. production process and unexploited energy by using . The development of strategic plans and a mathematical model. In [6], analysis using the operational decision making is facilitated by the Throughput Accounting (TA) metrics can be paired identification of bottlenecks and constraints. with the Six Sigma's research. The goal is to achieve . Optimal use of resources leads to improving the convergence between the Throughput Accounting profits and within the organization. and Six Sigma in order to improve the respective metrics. Whereas, many studies such as [17], [18], [19] The Theory of Constraints (TOC) is unique in its indicate that the theory of constraints principles work by focusing on the efficiency of the production include the following: process. This concept was first developed by Goldratt . The level of outputs achieved at the level of and Cox in 1986 in the United States. [7] introduced unrestricted resources is determined by the level with his book "The Goal" and developed this concept of the restricted system resources. in 1990 eventually. Theory of Constraints is the . The benefit and effectiveness of the system are common name in the United States [7], [8]. [9] not synonymous i.e., benefit is the operation of defines the Theory of Constraints as an unrestricted resources at full capacity to reduce administrative approach aimed at maximizing long- loss. While effectiveness is the extent of the term by addressing organizational bottlenecks system ability to achieve its goals regardless of or scarce resources in organization. [10] states that it the capacities level used in the production is the strategy of managing the organization to process. improve the time of the product cycle for ensuring . The throughput of time achieved at the level of the optimal flow of production. While [11] defines restricted resources equals the increase in the rate the TOC as a description of the methods used to of restricted resources outputs. maximize operating income when facing operations . The margin of time achieved at the level of to areas representing bottlenecks and other areas that unrestricted resources is considered complete do not represent bottlenecks. [11] also defines it: a illusion because the increase in idle time means system that seeks to determine how decisions are increased inventory. made and how to deal with the constraints for the . The transformation batch may not equal the production process which can be internal or external production batch. The transformation batch is the [12]. On the other hand, [13] shows that the TOC is amount of resources transferred from the an administrative philosophy that aims to achieve production process to the subsequent and usually continuous improvement through the process and less than the production batch represented by the management of constraints that prevent management amount of resources produced between the work from achieving its goals in the short term. The centers. researchers note that the theory of constraints is an

764 TEM Journal – Volume 9 / Number 2 / 2020. TEM Journal. Volume 9, Issue 2, Pages 763‐769, ISSN 2217‐8309, DOI: 10.18421/TEM92‐45, May 2020.

. The production batch must be changed because 3. Throughput Accounting of the different capacities between production processes. Bottlenecks or constraints occur in the The objective of the organization is gaining money production process. and performance measures. The progress shows the achieved goal. As a result, the current measurements Moreover, [20], [21], [22] identify the most of cost accounting lead either to loss of throughput, important steps to implement the Theory of increase in inventory or operating [23]. Constraints as follows: This is inconsistent with the objective of the . Identify constraints of the system: Constraints organization. Throughput Accounting requires the are limiting the optimal utilization of resources provision of more appropriate tools to stimulate these and represent the bottleneck in the system. There organizations. This approach contains the direct may be physical constraints such as materials, materials cost of the product only. The other costs are machinery, level of demand or administrative fixed because they cannot be allocated to the constraints such as procedures, methods and products [24]. Throughput Accounting is a modern policies. concept in managerial accounting to support Theory . Define how to exploit the constraints: Make of Constraints. The Throughput Accounting provides maximum use of the constraint and work to measurements to implement the main concepts of the exploit it in the best form. If the constraint is a Theory of Constraints [25]. Also, it helps identify raw material, it must be sure that there is no loss and measure the cost of production, sales and or damage. If the constraint is a policy, it must be increase productivity. At the same time, to reduce replaced by another policy that achieves the same inventory and operating costs and help management goal. to make optimal decisions [6]. The main concept of . Integration of all other elements to exploit the Throughput Accounting is use of profitability constraint: Find a kind of integration and analysis at the level of the organization rather than interdependence between restricted and the profit margin analysis at the product level. In unrestricted resources. The processing of contrast, the traditional cost accounting is collected bottlenecks is avoided for the unrestricted costs from all departments of the production process. resource and the formation of a new constraint. It is allocated in different ways to products. The cost . Working to raise the constraint: Through is subtracted from the selling price, and the profit increasing the production capacity of the margin of the product is reached [26]. Throughput resource restricted and increase market share or Accounting is defined as: a performance training of workers or increase their skills. measurement method that builds on the relationships . Evaluation and processing of the constraint between production, costs and throughput. The activity and return to the first step. products cost determined according to the Throughput Accounting depending on both the main The process of continuous improvement to products and resources [27]. They also define it as an overcome a certain constraint shows us another administrative tool that operates partly on the Theory constraint. Return to the first step to search about the of Constraints. The management focuses mainly to underlying causes of this constraint and improve the maximize profits rate by processing on bottlenecks system. The following figure illustrates the steps to [28]. Hansen defines it: An accounting approach to implement the Theory of Constraints to manage the evaluate the organization ability to maximize the constraints. effectiveness of the activity’s achievement through the use of financial measures. The optimal utilization Identify the constraint of restricted resources leads to attaining the goal within a given period [29]. [30] defines it as: the Exploitation of constraint system consists of a number from dependent variables to achieve goal units. The system reduces application limitations and improves performance by Support the exploitation of the constraint using system constraints. While Maynard defines it as: The accounting system seeks to maximize the return on the restricted resource activity [31]. The Raise the constraint researchers note that Throughput Accounting use to evaluate the company's performance effectively. It reaches the ultimate goal of generation by Evaluate and process the constraint minimizing constraints and bottlenecks in the work

environment. Throughput Accounting is not a system Figure 1. The Theory of Constraints for measuring and allocating costs, such as standard

TEM Journal – Volume 9 / Number 2 / 2020. 765 TEM Journal. Volume 9, Issue 2, Pages 763‐769, ISSN 2217‐8309, DOI: 10.18421/TEM92‐45, May 2020. costs and activity-based costing. It is a measure of . Time is the main element in the Throughput the added value from the organization's inflows Accounting approach for the purpose of applying in the form of or sales. The importance of costs on the units produced. It is called the this approach shows in continuous improvement to throughput time and represents the time spent to maximize throughput rather than reduce costs. convert the raw material to a finished product and sales. 4. The Role of Throughput Accounting in Cost In addition, the Throughput Accounting did not Measurement and Performance Assessment measure cost and evaluate performance according to the conceptual framework of measurement. It links Throughput Accounting is based on dividing the the amount of throughput achieved and the resources structure of the manufacturing costs elements consumed to achieve that throughput. according to their behavior to the raw material as the only variable element. The rest of the elements are 5. Research Methodology grouped into a single group called operating expenses which are fixed costs in the short term and This study depends on a basic hypothesis that the are predetermined costs. The quantity of inputs use of Throughput Accounting contributes to the needed to manufacture the product unit which are measurement of cost and evaluate the efficiency and manufactured and then sold and should not exceed; effectiveness of the organization performance at the or less than a certain amount because in case of application of the Theory of Constraints and adapted shortage the product is not completed. In the case of to the contemporary environment. increasing it will be transferred into and The sample contains (60) questionnaires the organization costs are increasing due to retention, distributed to the accounting, administrative, damage and loss. The major developments in the technical, engineering and production designers’ modern manufacturing environment have led to staffs at the State Company for Electrical Industries increased investments in machinery and equipment in Waziriya. The period of application for the and the disappearance of the direct labor component questionnaire was during 9/2019-11/2019. The State in the structure of industrial costs. Accordingly, raw Company for Electrical Industries in Waziriya is one material costs became the only variable component of the factories belonging to the General Company of costs as a result of the direct labor cost shifting to for Southern Cement, which is one of the formations the fixed cost category [30]. It identifies the strengths affiliated to the Ministry of Industry and Minerals. It and weaknesses of the organization in a fast and is located in Baghdad province. The company flexible manner [32]. [30] indicate that the produces the following products: fans, motors, performance measures that depend on Theory of refrigerators, heaters, air conditioners and various Constraints are; electrical equipment. The data used in this study were obtained by . Performance measures at the level of analyzing questionnaires distributed over the sample, organization performance such as net profit, including administrative, financial, productive and return on capital invested and cash flow. engineering staff in the factory. The authors . Performance measures at the level of internal determine the most important questions related to the performance such as internal operations surplus research. The individual’s opinions of the research i.e., sales revenue less the cost of direct materials sample identify and test the hypothesis of the and inventory. It represents any invested cash research using the fifth Likert method. It depend on a through the organization in the purchase of set of statistical indicators to conduct statistical materials and . These measures also include analysis, as follows: Test the hypothesis of research, the operating expenses that represent the cash which states: The use of Throughput Accounting paid by organizations to convert the inventory contributes to the measurement of cost and evaluate into internal operations surplus. the efficiency and effectiveness of the economic . Performance measures at the process level using unity performance at the application of the Theory of detailed cost information. Constraints and adapted to the contemporary . The theory of constraints concerns short-term business environment. measurements and neglects long-term vision required by strategic decisions.

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Table 1. Indicators of individual responses for hypothesis Throughput testing Accounting contributes to the Statistical Indicators development of cost systems in order to 9 provide relevant # Items 4.083 1.124 information for the 27.535% 81.667% mean mean Weight Weight Percent Percent purposes of planning, Standard Weighted Weighted Deviation arithmetic Coefficient of Variance of Variance control and evaluation of performance. The use of Throughput Accounting leads to the The organization 1 provision of accurate management is

cost measures in the 3.867 1.214 concerned with the use 31.393% 31.393% 77.333% organization. of Throughput Accounting to find Throughput 10 solutions of the

Accounting provides bottlenecks and 4.517 0.676 2 relevant information on constraints that affect 14.973% 90.333% the time of restricted 4.417 0.766

17.335% 17.335% 88.333% the efficiency and activities achievement. effectiveness of Throughput performance.

Accounting works on Throughput to provide relevant cost Accounting 3 information with the 4.050 4.050 1.156 11 contributes to the 28.544% 28.544% 81.000% modern manufacturing identification of 3.800 1.147 environment. 30.180% 76.000% unused capacity.

The product applies by There is a role for the cost of direct Throughput materials only without Accounting in the other operating 12 identifying costs. It is useful for 3.050 1.383 4 unnecessary activities 45.345% 61.000% measures of the added 4.017 1.172

29.168% 29.168% 80.333% that are not add value value of the inflows generated by the Throughput revenues. Accounting under the Theory of Constraints Assisting organization 13 helps reduce costs and in the measurement 3.950 1.156 maximizes 29.267% 79.000% and evaluation of profitability. performance through 5 the information Throughput 4.200 4.200 1.022 Accounting provided by 24.328% 84.000% Throughput contributes to 14 determining of

Accounting. 3.983 1.127

minimum inventory 28.302% 79.667% There is a need to levels. develop cost systems for give detailed Throughput information to evaluate Accounting 6 current and future contributes to the

performance, improve 4.267 0.989 provision of many

23.185% 23.185% 85.333% 15

the measurement and advantages that lead to 4.067 0.880 evaluation of the promotion of 21.650% 81.333% performance. competitiveness in the market. The development of cost systems contributes to the provision of integrated Mean

7 4.038 1.062

information on the 26.823% 80.756% 4.200 4.200 1.086

profitability of the 25.860% 84.000% product, the and the company. 6. Results and Discussion Increased competition requires the Results of Table 1. including 15 questions. It 8 development of current indicates that the overall response rate of the sample cost systems. 4.100 1.037 25.283% 25.283% 82.000% was 80.756 percent with a weighted mean of 4.038

and a standard deviation of 1.062 and a coefficient of variation of 26.823 percent. The tenth item is the most prominent item that contributes to the

TEM Journal – Volume 9 / Number 2 / 2020. 767 TEM Journal. Volume 9, Issue 2, Pages 763‐769, ISSN 2217‐8309, DOI: 10.18421/TEM92‐45, May 2020. enrichment of this variable: (Organization It is greater than the value of (T) filed 1.671 with a management is concerned with the use of degree of freedom 59 and a level of significance 5 Throughput Accounting to find solutions to per cent. This leads to the acceptance of the research bottlenecks and constraints that affect performance hypothesis, which states that: the use of Throughput efficiency and effectiveness). Severity of response Accounting contributes to cost measurement and 90.333 per cent and weighted mean 4.517, standard evaluates the efficiency and effectiveness of the deviation 0.676 vs. coefficient of variance 14.973 per performance of economic unity in applying the cent. The next item is the second item: (Throughput Theory of Constraints and adapted to the current Accounting offers relevant information on the period business environment. of minimal task achievement) as the magnitude of the response of 88.333 per cent on a weighted mean of 7. Conclusion

4.417 and the standard deviation of 0.766 on a The research focuses on the use of Throughput coefficient of variance of 17.335 per cent on a Accounting as an approach to the implementation of weighted mean of 17.335 per cent. Whereas the cost accounting systems in the modern manufacturing lowest percentage in this variable is the twelfth climate. Measures expenses and reviews the paragraph as the severity of the response of 61% with performance of the company. The importance of a weighted mean of 3,050 and a standard deviation of research stems from the role of Throughput 1,383 as against a coefficient of variation of 45,345 Accounting in resolving the negative effects of abuse per cent. The following table shows the test (T) for of capital in restricted activities. The benefit of one sample of the research hypothesis variables at the Throughput Accounting handles constraints and level of significance 5 per cent and the degree of calculates costs in the philosophy of the freedom 59 and all the research variables. implementation of constraints and in accordance with Table 2. T test results of the research variables the patterns in modern management accounting. The information provided by Throughput Accounting Variables Calculated (T) Tabulated(T) helps to measure costs and to evaluate the efficiency 1 5.530 1.671 and effectiveness of the organization's performance. 2 14.333 1.671 This helps to support planning and management 3 7.035 1.671 processes by optimizing achievement and reducing 4 6.722 1.671 inventory levels. The use of Throughput Accounting 5 9.097 1.671 in the context of the theory of constraints leads to 6 9.919 1.671 solutions to bottlenecks that affect the efficiency and 7 8.558 1.671 efficiency of performance. Results of the statistical 8 8.220 1.671 analysis of the study have shown that the general 9 7.464 1.671 average of the research hypothesis variables in which 10 17.372 1.671 the value of (T) measured 8.163 is greater than the 11 5.403 1.671 value of (T) defined 1.671 with a degree of freedom 12 0.280 1.671 59 and a level of significance 5 per cent. To accept 13 6.365 1.671 this hypothesis, which states that: the use of 14 6.756 1.671 Throughput Accounting leads to cost calculation and 15 9.385 1.671 tests the efficiency and effectiveness of the results of Mean 8.163 1.671 economic unity in applying the principle of constraints and adapted to the current business (df=59, significant level 5%) setting. Necessary to benefit from the information

It appears from the table above that the value of provided by Throughput Accounting for the treatment (T) estimated is greater than the value of (T) shown. of bottlenecks, reduce costs and decrease inventory. The degree of freedom 59 and the level of Reducing the time required for restricted tasks and significance 5 per cent for the variables of this maximizing capacity utilization by preventing time hypothesis, as well as the general rate of these loss. Helps top management to apply Throughput variables, where the value of (T) is calculated 8.163. Accounting as one of the new management accounting methods.

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