11.2 PERT/Cost

Although PERT is an excellent method of monitoring and controlling project length, it does not consider another very important factor, project cost. PERT/Cost is a modification of PERT that allows a manager to plan, schedule, monitor, and control cost, as well as time.

We begin this section by investigating how costs can be planned and scheduled. Then we see how costs can be monitored and controlled.

Planning and Scheduling Project Costs: Budgeting Process

The overall approach in the budgeting process of a project is to determine how much is to be spent every week or month. This is accomplished as follows:

Four Steps of the Budgeting Process

  1. Identify all costs associated with each of the activities. Then add these costs together to get one estimated cost or budget for each activity.

  2. If you are dealing with a large project, several activities can be combined into larger work packages. A work package is simply a logical collection of activities. Since the General Foundry project we have been discussing is small, each activity will be a work package.

  3. Convert the budgeted cost per activity into a cost per time period. To do this, we assume that the cost of completing any activity is spent at a uniform rate over time. Thus, if the budgeted cost for a given activity is $48,000 and the activity’s expected time is 4 weeks, the budgeted cost per week is $12,000 $48,000/4 weeks).

  4. Using the earliest and latest start times, find out how much money should be spent during each week or month to finish the project by the date desired.

Budgeting For General Foundry

Let us apply this budgeting process to the General Foundry problem. The Gantt chart for this problem, shown in Figure 11.9, illustrates this process. In this chart, a horizontal bar shows when each activity will be performed, based on the earliest times. To develop a budget schedule, we will determine how much will be spent on each activity during each week and add these amounts to the chart in place of the bars. Lester Harky has carefully computed the costs associated with each of his eight activities. He has also divided the total budget for each activity by the activity’s expected completion time to determine the weekly budget for the activity. The budget for activity A, for example, is $22,000 (see Table 11.5). Since its expected time (t) is 2 weeks, $11,000 is spent each week to complete the activity. Table 11.5 also provides two pieces of data we found earlier using PERT: the ES and LS for each activity.

Table 11.4 Impact of an Increase (Decrease) in an Activity Time for a Critical Path Activity

ACTIVITY TIME SUCCESSOR ACTIVITY PARALLEL ACTIVITY PREDECESSOR ACTIVITY
Earliest start Increase (decrease) No change No change
Earliest finish Increase (decrease) No change No change
Latest start Increase (decrease) Increase (decrease) No change
Latest finish Increase (decrease) Increase (decrease) No change
Slack No change Increase (decrease) No change
A graph represents the Gantt chart for General Foundry Example.

Figure 11.9 Gantt Chart for General Foundry Example

Looking at the total of the budgeted activity costs, we see that the entire project will cost $308,000. Finding the weekly budget will help Harky determine how the project is progressing on a week-to-week basis.

The weekly budget for the project is developed from the data in Table 11.5. The earliest start time for activity A, for example, is 0. Because A takes 2 weeks to complete, its weekly budget of $11,000 should be spent in weeks 1 and 2. For activity B, the earliest start time is 0, the expected completion time is 3 weeks, and the budgeted cost per week is $10,000. Thus, $10,000 should be spent for activity B in each of weeks 1, 2, and 3. Using the earliest start time, we can find the exact weeks during which the budget for each activity should be spent. These weekly amounts can be summed for all activities to arrive at the weekly budget for the entire project. This is shown in Table 11.6. Notice the similarities between this chart and the Gantt chart shown in Figure 11.9.

Do you see how the weekly budget for the project (total per week) is determined in Table 11.6? The only two activities that can be performed during the first week are activities A and B because their earliest start times are 0. Thus, during the first week, a total of $21,000 should be spent. Because activities A and B are still being performed in the second week, a total of $21,000 should also be spent during that period. The earliest start time for activity C is at the end of week 2 (ES=2 for activity C). Thus, $13,000 is spent on activity C in both week 3 and week 4. Because activity B is also being performed during week 3, the total budget in week 3 is $23,000. Similar computations are done for all activities to determine the total budget for the entire project for each week. Then these weekly totals can be added to determine the total amount that should be spent to date (total to date). This information is displayed in the bottom row of the table.

Table 11.5 Activity Cost for General Foundry, Inc.

ACTIVITY EARLIEST START TIME, ES LATEST START TIME, LS EXPECTED TIME, t TOTAL BUDGETED COST ($) BUDGETED COST PER WEEK ($)
A 0 0 2 22,000 11,000
B 0 1 3 30,000 10,000
C 2 2 2 26,000 13,000
D 3 4 4 48,000 12,000
E 4 4 4 56,000 14,000
F 4 10 3 30,000 10,000
G 8 8 5 80,000 16,000
H 13 13 2 16,000 8,000
Total 308,000

Table 11.6 Budgeted Cost ($1,000s) for General Foundry, Inc., Using Earliest Start Times

WEEK
ACTIVITY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 TOTAL
A 11 11 22
B 10 10 10 30
C 13 13 26
D 12 12 12 12 48
E 14 14 14 14 56
F 10 10 10 30
G 16 16 16 16 16 80
H 8 8 16
308
Total per week 21 21 23 25 36 36 36 14 16 16 16 16 16 8 8
Total to date 21 42 65 90 126 162 198 212 228 244 260 276 292 300 308

Those activities along the critical path must spend their budgets at the times shown in Table 11.6. The activities that are not on the critical path, however, can be started at a later date. This concept is embodied in the LS for each activity. Thus, if latest starting times are used, another budget can be obtained. This budget will delay the expenditure of funds until the last possible moment. The procedures for computing the budget when LS is used are the same as when ES is used. The results of the new computations are shown in Table 11.7.

Compare the budgets given in Tables 11.6 and 11.7. The amount that should be spent to date (total to date) for the budget in Table 11.7 is smaller in the first few weeks. This is because this budget is prepared using the latest start times. Thus, the budget in Table 11.7 shows the latest possible time that funds can be expended and still finish the project on time. The budget in Table 11.6 reveals the earliest possible time that funds can be expended. Therefore, a manager can choose any budget that falls between the budgets presented in these two tables. These two tables form feasible budget ranges. This concept is illustrated in Figure 11.10.

The budget ranges for General Foundry were established by plotting the total-to-date budgets for ES and LS. Lester Harky can use any budget between these feasible ranges and still complete the air pollution project on time. Budgets like the ones shown in Figure 11.10 are normally developed before the project is started. Then, as the project is being completed, funds expended should be monitored and controlled.

Although there are cash flow and money management advantages to delaying activities until their latest start times, such delays can create problems with finishing the project on schedule. If an activity is not started until its latest start time, there is no slack remaining. Any subsequent delays in this activity will delay the project. For this reason, it may not be desirable to schedule all activities to start at the latest start time.

Table 11.7 Budgeted Cost ($1,000s) for General Foundry, Inc., Using Latest Start Times

ACTIVITY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 TOTAL
A 11 11 22
B 10 10 10 30
C 13 13 26
D 12 12 12 12 48
E 14 14 14 14 56
F 10 10 10 30
G 16 16 16 16 16 80
H 8 8 16
308
Total per week 11 21 23 23 26 26 26 26 16 16 26 26 26 8 8
Total to date 11 32 55 78 104 130 156 182 198 214 240 266 292 300 308

Monitoring and Controlling Project Costs

The purpose of monitoring and controlling project costs is to ensure that the project is progressing on schedule and that cost overruns are kept to a minimum. The status of the entire project should be checked periodically.

Lester Harky wants to know how his air pollution project is going. It is now the sixth week of the 15-week project. Activities A, B, and C have been finished. These activities incurred costs of $20,000, $36,000, and $26,000, respectively. Activity D is only 10% completed, and so far the cost expended has been $6,000. Activity E is 20% completed with an incurred cost of $20,000, and activity F is 20% completed with an incurred cost of $4,000. Activities G and H have not been started. Is the air pollution project on schedule? What is the value of work completed? Are there any cost overruns?

A graph represents the budget ranges for general foundry.

Figure 11.10 Budget Ranges for General Foundry

A table shows monitoring and controlling budgeted cost.

Table 11.8 Monitoring and Controlling Budgeted Cost

In general, the project is still considered on schedule if the current week is less than the latest finish of all unfinished activities. The value of work completed, or the budgeted cost to date for any activity, can be computed as follows:

Value of work completed=(Percentage of work completed)×(Total activity budget)
(11-8)

The activity difference is also of interest:

Activity difference=Actual costValue of work completed
(11-9)

If an activity difference is negative, there is a cost underrun, but if the number is positive, there has been a cost overrun.

Table 11.8 provides this information for General Foundry. The second column contains the total budgeted cost (from Table 11.6), and the third column contains the percent of work completed. With these data and the actual cost expended for each activity, we can compute the value of work completed and the overruns or underruns for every activity.

One way to measure the value of the work completed is to multiply the total budgeted cost times the percent of work completed for each activity.3 Activity D, for example, has a value of work completed of $4,800 (=$48,000 times 10%). To determine the amount of overrun or underrun for any activity, the value of work completed is subtracted from the actual cost. These differences can be added to determine the overrun or underrun for the project. As you see, at week 6 there is a $12,000 cost overrun. Furthermore, the value of work completed is only $100,000, and the actual cost of the project to date is $112,000. How do these costs compare with the budgeted costs for week 6? If Harky had decided to use the budget for earliest start times (see Table 11.6), we can see that $162,000 should have been spent. Thus, the project is behind schedule, and there are cost overruns. Harky needs to move faster on this project to finish on time, and he must control future costs carefully to try to eliminate the current cost overrun of $12,000. To monitor and control costs, the budgeted amount, the value of work completed, and the actual costs should be computed periodically.

In the next section, we see how a project can be shortened by spending additional money. The technique is called crashing and is part of the critical path method (CPM).

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