Chapter 7: The Conversion Cycle

Review Questions:

1. Define the conversion cycle?

A conversion cycle transforms (converts) input resources, such as raw materials, labor
and overhead into finished products or services for sale.

2. What activities are involved in the batch processing system?

Plan and control production
Specifying materials and operations requirements
Production scheduling
Perform production Operations
Maintain Inventory Control
Perform Cost Accounting

3. Distinguish between continuous, batch, and made-to-order processing.

Continuous processing:
o Creates a homogenous product through a continuous series of standard procedures.
o Typically, under this approach firms attempt to maintain finished-goods inventory at
levels needed to meet expected sales demand.
o The sales forecast, in conjunction with information on current inventory levels,
triggers this process.
o Cement and petrochemicals are produced by this manufacturing method.
Batch processing:
o Produces discrete groups (batches) of products. Each item in the batch is similar and
requires the same raw materials and operations. To justify the cost of setting up and
retooling for each batch run, the number of items in the batch tends to be large.
o This is the most common method of production and is used to manufacture
products such as automobiles, household appliances, canned goods, automotive
tires and textbooks.
Make-to-order processing:
o Involves the fabrication of discrete products in accordance with customer
specifications.
o This process is initiated by sales orders rather than depleted inventory levels.

4. What documents trigger a support batch processing systems?

A batch processing system is triggered by either individual sales order from the
revenue cycle or by a sales forecast the marketing system provides.
 Production schedule is the formal plan and authorization to begin
production.
Bills of materials (BOM) specifies the types and quantities of the RM
and subassemblies used in producing a single unit of finished product
Route sheet shows the production path that a particular batch of
product follows during manufacturing
Work order (or production order) draws from BOM and route sheets
to specify the materials and production (machining, assembly and so on)
for each batch
Move ticket records work done in each work center and authorizes the
movement of the job or batch from one work center to the next
Materials requisition authorizes the storekeeper to release materials
(and subassemblies) to individuals or work centers in the production
process

5. What are the primary determinants for both materials and operations requirements?
o RM requirement the difference between what is needed and what is available in the RM
inventory
o This information comes from analysis of inventory on hand, the sales forecast, engineering
specifications (if any), and the BOM.
o A product of this activity is the creation of purchase requisitions for additional RMs.

6. What are the objectives of inventory control in the production process?

An objective of inventory control is to minimize total inventory cost while ensuring that
adequate inventories exist to meet current demand.

7. What document triggers the beginning of the cost accounting process for a given production
run?
The cost accounting process for a given production run begins when the production
planning and control department sends a copy of the original work order to the cost
accounting department.

8. What documents are needed for cost accounting clerks to update the work-in-process accounts
with standard charges?
o Inventory control sends copies of materials requisitions, excess materials requisitions and
material returns.
o The various work centers send job tickets and completed move tickets.
o Standard cost file provides standards.

9. What types of management reports ate prepared by the cost accounting system?
10. What document signals the completion of the production process?

o To evidence that a stage of production has been completed, a copy of the move ticket is sent
back to production planning and control to update the open work order file.
o Upon receipt of the last move ticket, the open work order file is closed.
 o The finished product, along with a copy of the work order, is sent to FG warehouse.
o Also, a copy of the work order is sent to inventory control to update the FG inventory
records.

11. What functions should be separated to segregate record keeping from asset custody?
1. Inventory control maintains accounting records for RM and FG inventories. This
activity is kept separate from the materials storeroom and from the FG
warehouse functions, which have custody of these assets.
2. Similarly, the cost accounting function accounts for WIP and should be separate
from the work centers in the production process.

12. Give an example for each of the ff. control activities in the conversion cycle: transaction
authorization, segregation of duties and access control.
13. Distinguish between computer-aided design and computer-aided manufacturing.

o Computer-aided design (CAD) systems increase engineers productivity, improve accuracy by

automating repetitive design tasks and allow firms to be more responsive to market
demands. CAD technology greatly shortens the time frame between initial and final design.
This allows firms to adjust their production quickly to changes in market demand. It also
allows them to respond to customer requests for unique products. The CAD systems often
have an interface to the external communication network to allow a manufacturer to share
its product design specifications with its vendors and customers.
o Computer-aided manufacturing (CAM) is the use of computers to assist the manufacturing
process. CAM focuses on the shop floor and the control of the physical manufacturing
process.
14. What is meant by the statement, Inventories camouflage production problems and can cause
overproduction? What is wrong with overproduction if you already own the raw material?
15. What are the primary goals of lean manufacturing?
Pull processing involves pulling products from the customer end (demand), rather than
pushing them from the production end (supply).
Perfect quality
Waste minimization
Inventory reduction
Production flexibility
Established supplier relations
Team attitude

16. Distinguish between activities and cost objects in activity-based costing.

o Activities describe the work performed in a firm. Preparing a purchase order, readying a
product for shipping or operating a lathe are examples of activities.
 o Cost objects are the reasons for performing activities. These include products, services,
vendors and customers. For example, the task of preparing a sales order (the activity) is
performed because a customer (the cost object) wishes to place an order.

17. Differentiate between essential and nonessential activities.

Essential activities add value; nonessential activities do not, and should be eliminated.

18. What is meant by the term islands of technology?

Islands of technology describes an environment in which modern automation exists in
the form of islands that stand alone within the traditional setting.

19. Define computer-integrated manufacturing.

o Computer-integrated manufacturing (CIM) is a completely automated environment with the
objective of eliminating non-value-added activities.
o A CIM facility makes use of group technology cells composed of various types of CNC
machines to produce an entire part from start to finish in one location.
o CIM supports flexible manufacturing by allowing faster development of high-quality
products, shorter production cycles, reduced production costs and faster delivery times.

20. Define the term value stream.

A companys value stream includes all the steps in the process that are essential to
producing a product.
 The master schedule for a production run coordinates the production of many
different batches.

The schedule is influenced by time constraints, batch size and specifications

derived from BOMs and route sheets.

The scheduling task also produces work orders, move tickets and materials
requisitions for each batch in the production run.

The actual production operations begin when workers obtain raw materials from
storekeeping in exchange for materials requisitions.
When the task is complete at a particular work center, the supervisor or other
authorized person signs the move ticket, which authorizes the batch to proceed to the
next work center.