Cost Accumulation
Cost Accumulation
OBJECTIVE
By the end of this lesson you should be able to describe the cost accumulation process for materials, labor
and overheads and solve computational problems
CONTENT
Cost accumulation
Define cost accumulation
Elements of cost: material, labor and overheads
Determination of costs in manufacturing, services and retail industries
Material costs
Ascertainment of material costs/classification.
Material cost records
Material purchasing procedures
Receipts, issue and storage of materials
Methods of valuing material issues.
Stores control procedures.
Ledger entries for material costs. (Introduction to cost book keeping)
Labour costs
Classification labor costs
Methods of labor remuneration
Labor control procedures
Maintenance of labor records
Wages department
Ledger entries for labor costs
Overhead costs
Definition
Types/Classification
Purposes of overhead cost analysis
Allocation and apportionment of overhead costs
Absorption of production overhead costs
Absorption of non-production overhead costs by cost units
Over or under absorption
Ledger entries for overhead costs
INSTRUCTIONS
Read the assigned study pack text
Reinforcement Questions 3.
3. MATERIAL COSTS
Materials refer to the tangible inputs into the process of producing useful output. They could be direct
materials or indirect materials (overheads) e.g. to produce tea, tealeaves is the material (input).
3.1 Material cost classification
Material costs may be classified as:
a) Direct Material Cost: Refers to costs of materials that may readily be identified with output
units. The cost of timber used in the manufacture of a chair is an example of a direct material.
b) Indirect Material cost: refers to items of raw materials for which it would be difficult and or
inefficient to attempt to charge directly to specific cost units. For example the glue used to bind
the joints in the assembly of a chair
Other examples of indirect materials include:
- Materials used by service departments e.g. spare parts used by maintenance department in
repairing and servicing plant and machinery
- Materials used by non production functions e.g. stationary used in accounting department
The material control system must attempt to ensure that the company does not incur costs in excess of an
agreed efficient level of expenditure. Lack of adequate control routines will result in the incidence of
costs in excess of an acceptable level, reduced profitability of production and increased operational costs.
Inventory Control and Management
The objectives of inventory management are
To ensure adequate stocks to allow for continuous operations/production, and
To minimize the cost of having inventory.
Inventory management is important since in most organizations it represents the largest single investment.
The major types of inventory are:
Raw materials
Work in progress
Finished goods
To achieve the above objectives of material cost costing , the manger has to make decisions regarding the
following:
a) What commodities to stock?
Use Material Requirement Planning
From the Master Production Schedule, the manager has determined the products to be produced.
A Bill of Materials can then be prepared. This lists in descending order the components required
to make the final product. The information required includes part name or description, part
number, next higher level assembly, required quality per end item, quantity per end item and
quantity required for the next higher level assembly.
Stores Ledger Account is also used to obtain information on what is currently available. The
file shows balance on hand as well as past data on how much is usually ordered, lead-time, and
safety stock.
From the above the manager can determine what need to be purchased.
b) How much to stock?
Use The Economic Order Quantity Model
This is a simple model that helps the manager to determine the optimum quantity of stock to
order so as to keep total costs at a minimum. The main costs of inventory are:
Holding or carrying costs
Ordering or set up costs
Shortage costs
To determine the economic order quantity the following formula may be used:
EOQ = √2 ChDCO
e) Increased supplier involvement in the design aspects of a product to ensure that they meet the
company’s quality requirements.
f) Maintenance of strict quality control by all parties.
Material Handling
The objective is to ensure that goods are delivered to the right places at the right time and in aright
manner to avoid delays, congestation and unnecessary handling. A big percentage of production costs is
taken up by material handling activities. A good material handling system should minimize these costs.
The manger needs to determine the type of equipment to be used to handle the material. The type of
equipment that is most frequently used includes:
Cranes
Lifts
Trucks
Conveyors
Towing
The factors that influence the type of equipment used includes:
Type of materials being moved
Volume
Rate or frequency of movement
Route of movement speed required
Method of storage employed
Safety or hazards involved.
EOQ = √ Ch
2 DCO
Illustration
The following information was extracted from the books of Danex Holdings regarding its stocks:
i. Reorder quantity 1,800
ii. Reorder period 4 weeks
iii. Maximum consumption 450 units/week
iv. Normal consumption 300 units/week
v. Minimum consumption 150 units/week
Vi Maximum reorder period 5 weeks
Vii Minimum reorder period 3 weeks
Required
Determine the following stock levels for Danex Holdings:
i. Re-order level
ii. Maximum stock level
iii. Minimum stock level
Solution
i) Re-order level = Maximum consumption X maximum reorder period
= 450 units X 5 weeks = 2,250 units
ii) Maximum stock level = reorder level + reorder quantity-
(Minimum consumption X minimum reorder period)
= 2250 + 1800 – (150 X3) = 4050 – 450 = 3600 units
iii) Minimum stock level = Reorder level – (Normal consumption X
normal reorder period)
= 2,250 – (300 X 4) = 2250 – 1200 = 1050 units
Total cost
Ordering costs Total cost
Ordering costs
0 Qx Quantity of Inventory
∴ ½ Q2Ch = D CO Q 2= √ 2DO
h
Q2Ch = 2D CO
Q2 =
2DCo
Ch
Therefore Q
√ 2DCo
Ch
Therefore EOQ=
√ 2DCo
Ch
EOQ = √
2DCo 2 X 1200 000X1000
= =4899 units
Ch 100
Illustration
Assume the following purchases were made in ABC Ltd
Date of purchase Units purchased Price/unit
1st January 500 100
2nd January 600 200
3rd January 800 400
Units used on 4th January are 900. Determine the value/cost of units used by using FIFO, LIFO and
weighted average.
Required:
Determine the cost of units used and the value of the closing stocks using FIFO, LIFO and Weighted
Average.
Solution
1. FIFO
Cost of units used
Date Units Unit price Total cost
Jan 1 500 100 50,000
Jan 2 400 200 80,000
900 Cost of units used 130,000
2. LIFO
Cost of units used
Date Units Unit price Total cost
Jan 3 800 400 320,000
Jan 2 100 200 20,000
900 Cost of units used 340,000
3. Weighted average
Date Units Unit price Total Cost of Issues
a) Direct labour cost may be defined as the cost of remuneration for employees efforts and skills
applied directly to a product or saleable service and which can be identified separately in product
costs.
Indirect labour cost may be defined as labour costs, which are not charged directly to a product.
The analysis of labour costs into direct or indirect cost depends upon the circumstances under
review
Examples include-
The wage paid to a worker who assembles components for a product is a direct cost while that
paid to a worker who is moving components for a range of products from one part of the factory
to another is an indirect cost.
b) Fixed cost in relation to labour is where by an employee is paid a fixed weekly wage irrespective
of the output produced cost varies directly with level of activity, for example where wages are
paid at a rater per unit.
c) Variable Labour Cost varies directly with level of activity, for example where wages are paid
per unit.
d) Controllable labour cost is a cost, which can be influenced by the actions of a person in whom
authority for such control is vested. The control of labour costs will be influenced by the method
of remuneration and the degree of management control, which is exercised.
Uncontrollable labour costs cannot be influenced by an officer in the organization, for example,
wage rise agitated by the trade union is an uncontrollable labour cost.
4.3 Time Keeping
A labour cost control routine should ensure that payments are paid only to employees who have
spent time at the work place and that payments are at agreed rates of pay including overtime
premium and shift premium payments where relevant.
Where an employee is paid a fixed sum for an agreed length of working week, it may be decided by a
check by the supervisor that the employee is at work is all that is necessary.
Where the employee is being paid at the rate per hour for the time spent at work together with premium
rates for overtime work, it is likely that a detailed record of time spent on the premises is required. This is
done by having the employee to register his arrival and departure times.
Worker A B C
Time allowed per unit (hrs) ¼ 1/6 ½
Units produced 474 684 175
Units rejected 54 84 25
Time taken (hrs) 78 72 80
Basic Pay per hour (Kshs) 6 6 3
Required
From the above information calculate for each employee
a) Bonus hours and amount of bonus paid
b) Gross wages earned
c) Labour cost for each good unit sold
Solution
4.3.1 Worker A
Total time saved = Expected time – Time taken
= ¼ (474 – 54) – 78 = 1/4/ X 420 – 78
= 105 – 78 = 27 hours
Accepted time saved = 50/100 x 27 = 13.5 hrs
Therefore bonus hours = 13.5 hours
Bonus pay = 13.5 x 6 = Shs 81
Worker B
= 1/8 (684 – 84) = Shs 100
Time saved = 100 – 72 = 28 hours
Bonus hours = 28/100 X 50 = 14 hours
Bonus pay = 14 x 6 = Shs 84
Worker C
= ½ (175 – 25) = 150/2 = 75 hours
Time saved = 75 – 80 = - 5
Bonus hours =0
Illustration 2
Based on the data below you are required to calculate the remuneration of each employee as determined
by each of the following methods
i. Hourly rate
ii. Basic piece rate
iii. Individual bonus scheme where the employee receives the bonus in proportion of the time
saved to time allowed
Solution
Salmon Roala Pike
i. Hourly rate 40 x 125 38 x 105 16 x 120
= 5000 = 3990 = 4320
Paye
C
NI D D
Other deductions E
Bank Y Employees NI D
Employees NI F
Other deductions Account
Bank Z
E
Wages Account
NI Account F
Cash/Bank Account
Net payment B
PAYE X
NI Y
Other deduction Z
5.0 OVERHEAD COSTS
5.1 Introduction
Overhead costs may be defined as the total cost of indirect materials, indirect labour and indirect
expenses. They may occur or be charged to:
a) Production cost centers i.e. making, finishing and packing departments.
b) Service costs centers for example maintenance and power generation
c) Other non production cost centers for example administration, selling and distribution
In this section, we will look at how these overhead costs are changed to production and non-
production departments so as to determine the total cost incurred by every department in the
organization.
cost analysis
There are a number of situations in which the analysis of overhead costs will assist in the
satisfactory evaluation of the relevant cost data. These include:
Absorption Costing
The process described in this lesson by which total overheads are absorbed into production naturally
enough is known as absorption costing. The absorption of total overheads into product costs has
implications for performance measurement, cost control and stock valuation and students should be aware
that the process described is subject to criticism by some managers and accountants.
The criticism arises from the fact that overheads contain items, known as fixed costs – which do not
change when the activity level changes and which would still have to be paid if there was no activity, e.g.
rates – and items, known as variable costs, which vary more or less directly with activity, e.g. power
consumption. To overcome some of the difficulties, an alternative method of costing has been developed,
known as marginal costing, which, although using the process of absorption, excludes fixed costs from
the absorption process.
COST ELEMENTS
Stage 1 Wa Sala Ma Ex
Two way
Coding by cost department of type of
Coding
expenditure and location of
Stage 2
Cost Analysis
Allocation
Apportionment Service
Ov e.
Stage 3
Production
Ov Ov Ov Ov Ov
Cost Centres
Stage 5 ● ● ● ● ●
● ● ● ● ●
Overhead Absorption ● ● ● ● ●
State 6 ● ● ● ● ●
COST UNITS
Figure 9.1
Stage 1. Cost Elements
The raw data relating to Labour, Materials, Expenses are gathered from Invoices, Payroll,
Goods Issued Notes and Requisitions.
Stage 2. Coding
All the raw cost data needs to be classified and then coded in respect of the type of expense
and location. This process is fundamental to all costing and management accounting
procedures.
Stage 3. Cost Analysis
Where discrete items of cost can be allotted to cost centers this is termed allocation. Where
the cost has to be spread or shared over several cost centers this is known as apportionment.
Stage 4. Service Cost Centres
These are cost centers which provide a service to production cost centers. Examples are
Maintenance, Sores and Boiler House. Their costs are built up by the usual process of
allocation and primary apportionment and then their total costs are apportioned (secondary
apportionment) over the production cost centers, thus forming part of production overheads
which are absorbed into the cost units produced. The problems of service cost centers are
dealt with in more detail below.
Stage 5. Production Cost Centres
These are the cost centers involved directly in the production process. Typical examples are,
the Assembly shop, Drilling machines, Centre lathes, Spray Shop.
Stage 6 Overhead Absorption
The overheads of each production cost centre are absorbed into the costs of the units
produced, usually in proportion to the time involved, i.e. by the Labour Hour or Machine
Hour Rate.
Required
Calculate the final distribution of overheads to cost centers including the reapportionment of maintenance
and power generation service costs to user cost centers where
a) The reciprocal nature of maintenance and power generation center is ignored.
b) The elimination method is used whereby the costs of each service center are apportioned in turn
between users but once they have been apportioned they are eliminated from any subsequent
apportionment
c) The repeated distribution method is used taking into account the reciprocal nature of the
service costs
d) An algebraic approach is used as an alternative to the repeated distribution method
Solution
a) The Direct Method Ignoring reciprocal service charges
Overhead cost allocation and apportionment statement
Basis of Making Finish Packing Maint Power Admin. Selling Distribu Total
Allocation ing tion
Service reapportionment
Maintenance 11525 1152 2305 (23050) 1441 2305 4302
Power 17622 2837 2837 (26100) 1702 567 1135
Total Costs 69847 19789 18642 0 0 34443 14472 19707 176900
d) Algebraic approach
This method requires that the reciprocal nature of the service costs is expressed in a set of
simultaneous equations which are solved by matrix algebra
Let x = Total cost of the maintenance cost center
Let y = Total cost of the power generating cost center
Then x = 23050 + 0.20Y
Y = 26100 + 0.20x
In a matrix equation it is
1 -0.08 24050
-0.2 1 26100
The percentage distribution of the service in the repeated distribution calculation summary shown above
are then applied to the total cost figures x and y
For example for the making cost center
Maintenance cost to making cost center = Kshs 25546 x 40% = Shs. 10,218
Power to cost to making cost center = Kshs 31209 x 60% = Shs. 18,726
Note
You can also use the simultaneous equation solving method to arrive at exactly the same answers above
(Shs.25,546 and shs.31,209). Probably, this is more popular than the matrix.
Illustration 2
The budgeted production overheads and other budgeted data of calculata Ltd are as follows:
Budget
Overhead cost for the period = Kshs 36,000 Production department
Direct material cost Kshs 32000
Direct labour cost Kshs 40000
Machine hours Kshs 10000
Direct hours of labour Kshs 18000
Units of output Kshs 10000
Required
Determine the absorption rate of the overheads
Solution
Total overhead costs to be absorbed = Kshs 36000
Absorption rate Calculation
a) Direct material cost 36000 x 100 = 112.50%
32000
b) Direct labour 36000 x 100 = 90%
40000
c) Machine hours shs 36000 = Shs 3.6/machine hour
10000 hrs
d) Labour direct hours shs 36000 = Shs 2/direct hour
18000 hrs
b) Production cost per each absorption base = Prime cost + Overhead cost
Prime cost + Overhead cost = Product cost
Direct material cost 165 + 90.00 = 225.00
Direct labour cost 165 + 72.00 = 237.00
Prime cost 165 + 82.50 = 247.50
Machine hours 165 + 82.80 = 247.80
Labour hours 165 + 72.00 = 237.00
Illustration 3
The following is the budget of Superb Engineering Works for the year 2002
Factory overheads Kshs 62,000
Direct labour cost Kshs 98,000
Direct labour hours 155,000
Machine hours 50,000
Actual labour hours were 40,000
Actual machine hours were 30,000
Actual direct labour costs were Kshs 50,000
Actual direct material costs were Kshs 45,000
Required
a) Determine the overhead application rate on the basis of
i. Direct labour hours
ii. Direct labour cost
iii. Machine hours, and
iv. Overhead costs
v. Production cost
Solution
i. Direct labour hours method
62,000
= Shs .0 . 4/labour hour
Overhead application rate (OAR) = 15,500
ii. Direct labour cost method
62,000
x 100= 63 .27%
98,000
OAR =
Production overheads will be absorbed by jobs or products at the pre-determined rater per machine hour.
If the actual number of machine hours used differs from the number used in the calculation of the
overhead absorption rate, an over or under absorption will occur.
Note that this problem does not occur with variable overheads since the incidence of the cost (such as
power cost) varies with changes in activity.
Illustration 4
Using data from figure 5.0 assume that the production overhead absorption rate was calculated where an
activity of 200 machine hours was estimated. Prepare a summary showing any over or under absorption
of overhead cost where the actual machine hours charged to jobs turns out to be
a) 150 hours
b) 250 hours
Solution
Absorption rate is Shs. 5.50 per machine hour. This may be analysed into fixed rate Shs.2.50 per machine
hour and variable rate; Shs. 3 per machine hour.
Required
1. Calculate the over and under absorption of variable overhead and fixed overhead cost
2. Comment on possible causes of over or under absorption figures
Solution
Variable overhead cost
Actual cost incurred Shs.6400
- Overhead absorbed 3000 hrs x Shs. 2 Shs.6000
Shs. 400
The fixed overhead absorption rate 9000/3000 machine hours = Shs. 3 per machine hour.
The actual activity level of 3000 machine hours is the same as that budgeted. The over absorption of fixed
overhead is therefore due to expenditure factors. It may have occurred because of the combination of
a) A lower price of a fixed item e.g. salary may be lower than budgeted
b) A reduced usage of what was classified as a fixed cost item e.g. the quantity of oil used to
lubricate the machines.
5.2.6 Absorption of non production overheads in production cost
Product costs may be compiled for a range of purposes including
a) Stock valuation
b) Product pricing
c) Decision making
For stock valuation purposes International Accounting Standard No. 2 define cost being that expenditure
which has been incurred in the normal course of business in bringing the product or service to its present
location and condition. This expenditure should include in addition to the cost of purchase such costs of
conversion as are appropriate to that location and condition.
Costs of conversion include production overheads and other overheads attributable in the particular
circumstances of the business in bringing the product or service to its present location and condition
For product pricing purposes, administration, selling and distribution overheads may be absorbed in a
number of ways including
a) As a percentage of selling price
b) As a percentage of full cost of production
c) As a percentage of conversion costs
d) As a rate per unit sold
For decision making purposes it is also relevant to know which part of administration selling and
distribution overhead costs are directly attributable to a particular product and which are avoidable if that
product is discontinued.