Process Costing
Process Costing
Process costing:
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Contents
Introduction .................................................................................................................................................. 3
Cost and management accounting definition........................................................................................... 3
Process costing systems design ................................................................................................................ 3
Flow of production and costs in a process costing system ....................................................................... 4
5 Steps in Process Costing............................................................................................................................. 5
Types of Process Costing .......................................................................................................................... 6
PROCESS ACCOUNT....................................................................................................................................... 7
a) Process costing when all output is fully completed .............................................................................. 7
1. When there are no losses in the process. ........................................................................................... 8
2. Normal losses in the process with no scrap value ............................................................................. 8
3. Abnormal losses in the process with no scrap value. ........................................................................ 9
4. Normal loss in the process with scrap value. .................................................................................. 10
5. Abnormal losses in the process with scrap value ............................................................................ 11
Abnormal gains with a scrap value. ............................................................................................................ 12
Process costing with ending work in progress partially completed ....................................................... 13
Elements of cost with different degrees of completion ......................................................................... 14
Previous process costs ............................................................................................................................ 16
Pros and Cons of Process Costing........................................................................................................... 17
Pros of process costing: .............................................................................................................................. 17
References .................................................................................................................................................. 19
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Introduction
As per the Chartered Institute of Management Accountants (CIMA) London, cost means ―the
amount of expenditure (actual or notional) incurred on, or attributable to, a given thing.
However, the interpretation of the term depends on several factors such as the nature of the
business or industry. It goes without saying, however, that it is difficult to determine an exact
cost or a true cost because no figure of cost is true under all circumstances and for all purposes.
(Daniels, 2017) Defines cost and management accounting as a break away from accounting that
aims to maximize profit while managing revenues and expenses. It pulls from data reports used
by managers to inform the different strategies designed around the long-term profit and growth
patterns of the organization.
Cost Leadership: - implies producing goods or provision of services at the lowest cost while
maintaining quality, to have a better competitive price (India). Michael E. Porter in his theory of
Generic Competitive Strategies has described this as one of the three key strategic dimensions
among ‘Product differentiation’ and ‘Focus or Niche’ to achieve competitive advantage in the
industry.
This is where cost management comes into play. Cost leadership in line with the subject of cost
and management accounting is achievable in an entity with a strong management accounting
system in place. (India I. o.) Explains that the main objective of costing is to analyze financial
records to distribute expenditure and allocate resources carefully to selected cost centers while
building up a total cost for the departments, processes, or jobs/contracts available to undertake.
Where a product passes through different specialized stages or processes, the output of one
process being the input of the subsequent process, it is best practice to ascertain the cost of each
stage or process of production which is known as process costing (India I. o.).
Process costing system is used in industries where masses of similar products or services are
produced in a flow process; products are produced in the same manner and consume the same
amount of direct costs and overheads. It is therefore unnecessary, and often impossible, to assign
costs to individual units of output. Instead, the average cost per unit of output is calculated by
dividing the total costs assigned to a product or service for a period by the number of units of
output for that period. Process costing is also used in textile industries, chemical industries, oil
refineries, soap manufacturing, paper manufacturing, tanneries, brewing among others. For
example, one liter of beer that is produced is identical to another litre so the cost of one litre is
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identical to another. This method is used where it is difficult to trade the item of prime cost to a
particular order because its identity is lost in the volume of continuous production.
The flow of production and costs in a process costing system is illustrated later in the diagram. It
should be noted that production moves from one process (or department) to the next until final
completion occurs. Each production process performs some part of the total operation and
transfers its completed production to the next process, where it becomes the input for further
processing. The completed production of the last process is transferred to the finished goods
inventory. The cost accumulation procedure follows this production flow. Control accounts are
established for each process (or department) and direct and indirect costs are assigned to each
process. A process costing system is easier to operate as many of the costs that are indirect in a
job costing system (an expense monitoring system that assigns manufacturing costs to each
product, enabling managers to keep track of expenses (Drury, 2008)) may be regarded as direct
in a process costing system. For example, supervision and depreciation that is confined to one
process would be treated as part of the direct costs of that process, since these costs are directly
attributable to the cost object (i.e. the department or process). As production moves from process
to process, costs are transferred with it.
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In contrast, job costing relates to a costing system where each unit or batch of output is unique.
This creates the need for the cost of each unit to be calculated separately. Basically, these two
costing systems represent extreme ends. The output of many organizations requires a
combination of the elements of both job costing and process costing.
1. Analyze inventory: Analyze the flow of items during the period to determine the amount of
inventory at the beginning of the period, how many items were started during the period, how
many were completed and transferred out and how many were incomplete at the end of the
period.
2. Calculate equivalent units: Process costing uses the concept of equivalent units to account
for items that are unfinished at the end of each period. For this step, multiply the number of
incomplete units at the end of the period by a percentage representing their progress through
the production process. For example, if there are 2,000 units of inventory still in progress and
they’re 75% complete, they are equivalent to 1,500 units for process costing purposes (2,000
x .75 = 1,500 units).
3. Calculate applicable costs: Total the costs for all production stages, including both direct
materials and conversion costs.
4. Calculate cost per unit: Divide the total cost by the number of units. This calculation
includes both completed units and equivalent units. So, if a business completed 4,000
products and another 1,000 units got halfway through production, the applicable costs would
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be divided by 4,000 + (1,000/2) = 4,500 units. If all the costs added up across all departments
to produce those units were $16,875, simply divide the cost by the number of units to arrive
at $3.75 per unit produced.
5. Allocate costs to complete and incomplete products: Allocate costs for the completed and
ending work-in-progress inventory to the corresponding accounts. This helps determine how
much money is tied up in current work-in-progress inventory. In the above example, since
the equivalent of 500 units are in progress and it cost $3.75 to produce each unit, the work-
in-progress inventory cost is $1,875 (500 x $3.75). And the complete product inventory cost
is 4,000 x $3.75 = $15,000.
Weighted average costs: This is the simplest method of calculating cost. Companies add all
costs for the current period and divide by the total number of units completed and transferred
out, plus the equivalent units of work-in-progress at the end of the period. It’s used for cases
where cost fluctuations from period to period are minor.
Standard costs: This method uses an estimated standard cost for each process stage instead
of actual costs. Companies typically use this method when it’s too difficult or time-
consuming to collect current information about the real costs. It can also be beneficial for
businesses that make a wide range of items and find it challenging to attribute precise costs to
each of the products. The estimated totals are compared to actual totals after a production run
is finished, and the difference is added to a variance account.
First in, first out (FIFO): The most complicated process costing approach, FIFO is used to
obtain more precise product costing, especially in situations where costs change significantly
from one period to the next. FIFO assumes that the first units in (i.e., work in progress at the
beginning of the current period) are the first to be completed. When calculating costs for the
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current period, it excludes costs incurred during the previous period for those beginning
work-in-progress units.
PROCESS ACCOUNT
Process accounts represent work in progress accounts. Inputs are debited to the process account
and the output from the process is entered on the credit side. The transfer to the next process or
finished goods inventory is at the cost of normal production. The abnormal losses are reported
separately in the abnormal loss account and are written off to the profit and loss statement as
period costs i.e. they are charged to the period in which they arise.
Process account
Unit Unit
Item Units Cost Amount Item Units Cost Amount
Material Costs xx x xxx Normal Loss xx x xxx
Labour Costs xx x xxx Output xx x xxx
Overhead
Costs xx x xxx Abnormal Loss xx x xxx
Abnormal
Gain xx x xxx Closing stock xx x xxx
Total xx x xxx xx x xxx
During the production process, a lot of things happen that is profit and losses may occur both
abnormal and normal, as discussed below
Example:
Bamwe Company produces a liquid fertilizer within a single production process. During the
month of May the input into the process was 12,000 litres at a cost of ugx120, 000. There were
no opening or closing inventories and all output was fully complete. Prepare the process account
and calculate the cost per litre of output for the single process for each of the six cases listed
below:
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Case Input Output Normal Abnormal Abnormal Scrap value of
(litres) (litres) loss(litres) loss(litres) gain spoilt
(litres) output(UGX per
liter)
1 12000 12000 0 0 0 0
2 12000 10000 2000 0 0 0
3 12000 9000 2000 1000 0 0
4 12000 10000 2000 0 0 5
5 12000 9000 2000 1000 0 5
6 12000 11000 2000 0 1000 5
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Case two process account:
𝑪𝒐𝒔𝒕−𝒔𝒄𝒓𝒂𝒑 𝒗𝒂𝒍𝒖𝒆
Unit cost =
𝒆𝒙𝒑𝒆𝒄𝒕𝒆𝒅 𝒖𝒏𝒊𝒕𝒔
𝟏𝟐𝟎𝟎𝟎𝟎−𝟎
Unit cost=
𝑰𝒏𝒑𝒖𝒕−𝑵𝒐𝒓𝒎𝒂𝒍 𝒖𝒏𝒊𝒕𝒔
𝟏𝟐𝟎𝟎𝟎𝟎
Unit cost = =12/=
𝟏𝟐𝟎𝟎𝟎−𝟐𝟎𝟎𝟎
Unit Unit
Item Units Cost Amount Item Units Cost Amount
Material Costs 12000 10 120,000 Normal Loss 2000 0 0
Output 10000 12 120000
Abnormal Loss 0
𝑪𝒐𝒔𝒕−𝒔𝒄𝒓𝒂𝒑 𝒗𝒂𝒍𝒖𝒆
Unit cost =
𝒆𝒙𝒑𝒆𝒄𝒕𝒆𝒅 𝒖𝒏𝒊𝒕𝒔
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𝟏𝟐𝟎𝟎𝟎𝟎−𝟎
Unit cost =
𝑰𝒏𝒑𝒖𝒕−𝑵𝒐𝒓𝒎𝒂𝒍 𝒖𝒏𝒊𝒕𝒔
𝟏𝟐𝟎𝟎𝟎𝟎
Unit cost = =12
𝟏𝟐𝟎𝟎𝟎−𝟐𝟎𝟎𝟎
Unit Unit
Item Units Cost Amount Item Units Cost Amount
Material Costs 12000 10 120,000 Normal Loss 2000 0 0
Output 9000 12 108000
Abnormal Loss 1000 12 12000
𝐶𝑜𝑠𝑡−𝑠𝑐𝑟𝑎𝑝 𝑣𝑎𝑙𝑢𝑒
Unit cost =
𝑒𝑥𝑝𝑒𝑐𝑡𝑒𝑑 𝑢𝑛𝑖𝑡𝑠
120,000−(5∗2000)
Unit cost =
𝐼𝑛𝑝𝑢𝑡−𝑁𝑜𝑟𝑚𝑎𝑙 𝑢𝑛𝑖𝑡𝑠
110000
Unit cost = 12000−2000=11
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Unit Unit
Item Units Cost Amount Units Cost Amount
Material Costs 12000 10 120,000 Normal Loss 2000 5 10,000
Output 10000 11 110,000
Abnormal Loss 0
𝑪𝒐𝒔𝒕−𝒔𝒄𝒓𝒂𝒑 𝒗𝒂𝒍𝒖𝒆
Unit cost =
𝒆𝒙𝒑𝒆𝒄𝒕𝒆𝒅 𝒖𝒏𝒊𝒕𝒔
𝟏𝟐𝟎,𝟎𝟎𝟎−(𝟓∗𝟐𝟎𝟎𝟎)
Unit cost =
𝑰𝒏𝒑𝒖𝒕−𝑵𝒐𝒓𝒎𝒂𝒍 𝒖𝒏𝒊𝒕𝒔
𝟏𝟏𝟎𝟎𝟎𝟎
Unit cost = =11
𝟏𝟐𝟎𝟎𝟎−𝟐𝟎𝟎𝟎
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Unit Unit
Item Units Cost Amount Units Cost Amount
Material Costs 12000 10 120,000 Normal Loss 2000 5 10,000
Output 9000 11 99,000
Abnormal Loss 1000 11 11,000
𝑪𝒐𝒔𝒕−𝒔𝒄𝒓𝒂𝒑 𝒗𝒂𝒍𝒖𝒆
Unit cost =
𝒆𝒙𝒑𝒆𝒄𝒕𝒆𝒅 𝒖𝒏𝒊𝒕𝒔
𝟏𝟐𝟎,𝟎𝟎𝟎−(𝟓∗𝟐𝟎𝟎𝟎)
Unit cost =
𝑰𝒏𝒑𝒖𝒕−𝑵𝒐𝒓𝒎𝒂𝒍 𝒖𝒏𝒊𝒕𝒔
𝟏𝟏𝟎𝟎𝟎𝟎
Unit cost = =11
𝟏𝟐𝟎𝟎𝟎−𝟐𝟎𝟎𝟎
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Unit Unit
Item Units Cost Amount Units Cost Amount
Material Costs 12000 10 120,000 Normal Loss 2000 5 10,000
Abnormal gain 1000 11 11,000 Output 11000 11 121,000
P&L
The net cost incurred in the process is UGX115, 000 (UGX120, 000 input cost less 1,000 litres
spoilt with a sales value of UGX5 per liter) the gain actually offsets the cost; this implies that the
gain is subtracted from the cost of production.
You will see that the abnormal gain has been removed from the process account and that it is
valued
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example, if 8,000 units were started and completed during a period and another 2,000 units were
partly completed then these two items cannot be added together to ascertain their unit cost. We
must convert the work in progress into finished equivalents (also referred to as equivalent
production) so that the unit cost can be obtained. To do this, we must estimate the percentage
degree of completion of the work in progress and multiply this by the number of units in
progress at the end of the accounting period. If the 2,000 partly completed units were 50 per cent
complete, we could express this as an equivalent production of 1,000 fully completed units. This
would then be added to the completed production of 8,000 units to give a total equivalent
production of 9,000 units. The cost per unit would then be calculated in the normal way. For
example, if the costs for the period were Ugx180, 000 then the cost per unit completed would be
ugx20 (ugx180, 000/9,000 units) (ugx)
Completed units transferred to the next process 160000
(8000@ugx20)
WIP (1000 units @ ugx 20) 20000
Total 180000
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Materials are added at the start of process A and at the end of process B and conversion costs are
added uniformly throughout both processes. The closing work in progress is estimated to be 50
per cent complete for both processes; the process account will look like the following.
Calculation of cost per unit for process A
Cost element Total cost Completed WIP Total Cost per unit
units equivalent (cost/total
units units)
Material 210,000 10,000 4000 14000 15
Conversion 144,000 10,000 2000 12000 12
Total 354,000 27
You will see from the above statement that details are collected relating to the equivalent
production for completed units and work in progress by materials and conversion costs. This
information is required to calculate the cost per unit of equivalent production for each element of
cost. As materials are issued at the start of the process, any partly completed units in ending
work in progress must be fully complete as far as materials are concerned. Therefore, an entry of
4,000 units is made in the work in progress equivalent unit’s column. Regarding conversion cost,
the 4,000 units in progress are only 50 per cent complete and therefore the entry in the work in
progress column for this element of cost is 2,000 units. To compute the value of work in
progress, the unit costs are multiplied separately by the materials and conversion cost work in
progress equivalent production figures. Only one calculation is required to ascertain the value of
completed production. This is obtained by multiplying the total cost per unit of ugx27 by the
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completed production. Note that the cost of the output, including work in progress, of ugx354,
000 in the above statement is in agreement with the cost of input of ugx354, 000
You will see that the previous process cost is treated as a separate cost in the table, and, since
this element of cost will not be added to in process B, the closing work in progress must be fully
complete as far as previous process cost is concerned. Note that, after the first process, materials
may be issued at different stages of production. In process B, materials are not added until the
end of the process, and the closing work in progress will not have reached this point; the
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equivalent production for the closing work in progress will therefore be zero for materials.
Normally, material costs are introduced at one stage in the process and not uniformly throughout
the process. If the work in progress has passed the point at which the materials are added then the
materials will be 100 per cent complete. If this point has not been reached then the equivalent
production for materials will be zero.
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Calculation difficulties (equivalent units): Process costing also relies on calculations of
equivalent units, which are determined by assigning costs to unfinished goods at the start or
end of an accounting period. Companies include the value of this work in process on balance
sheets. The real cost of these unfinished goods can vary, for example if the price of raw
materials fluctuates from month to month. If companies don’t accurately estimate the cost of
work-in-progress items, they’ll end up with inaccurate product costs.
Time consuming: Calculating equivalent units can be time consuming. Management
accountants must determine how far down the line in the production process these unfinished
goods are and assign costs accordingly.
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References
(n.d.). Retrieved from https://www.myaccountingcourse.com/accounting-dictionary/job-costing
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