Module 1 Process
Module 1 Process
PROCESS COSTING
Meaning and Definition: There are certain industries in which one or more products are
manufactured in a continuous flow or on mass production basis. The raw material passes
from process to process until the finished product comes out. Similarly, the output of the
first process becomes the raw material of the second process and the output of the second
process becomes the raw material of the third process and so on, until the finished product is
obtained. The method of process costing is applied in such industries.
According to CIMA, “process costing is that form of operation costing where
standardised goods are produced”.
Costs are determined for each job separately. Costs are computed for each process.
As the job as a whole is considered as a single As there are series of processes employed, the
unit, there is no transfer of one part of job to cost of one process is transferred to the other
another. process
Work in progress may or may not occur in the There is usually work in progress, since the
beginning or at the end production is continuous in nature.
Cost control becomes difficult due to the On account of continuous and uninterrupted
intermittent nature of production. production, cost control is comparatively
easier.
There is no joint or by products. Production may give rise to joint or by
products.
Costs are computed when a job is complete. Costs are calculated at the end of each process.
Elements of process costing are direct materials, direct labour, direct expenses and
overheads
Format of process account
Process 1 A/c
Particulars Units Amount Particulars Units Amount
To direct materials By normal loss
Process II A/c
Particulars Units Amount Particulars Units Amount
To process I (cost of By normal loss
output transferred
from process I)
To direct materials
To direct labour
To direct expenses
By process III a/c
To factory overheads or finished stock a/c
1. A product has to pass through P, Q, R processes for completion. During a month, 1000
units were produced for which the following was the expenditure.
P Q R
Materials 2500 5000 2500
Labour 12500 10000 7500
Direct expenses 1250 1500 2500
There was a common expenditure of Rs.15000 which was to be allocated on the basis of
direct wages. Raw materials worth Rs.15000 were issued to process P. Prepare the
process accounts and finished stock account.
Process loss or wastage
The process loss or wastage may be divided into two: normal loss and abnormal loss
Normal loss: It is the quantity of wastage which is unavoidable and is bound to take place.
It cannot be avoided though efforts can be made to minimise it. Normal loss generally arises
on account of the nature of materials used or the nature of the manufacturing process
involved. The extent of normal loss can be ascertained on the basis of past experience.
Normal output (units) = Total input (units) – Normal loss (units)
Abnormal loss: It is defined as the loss in excess of the predetermined (normal) [Link] may
occur due to unexpected or abnormal conditions such as carelessness of workers, accident,
substandard materials etc.
Abnormal output (units) = normal output (units) - actual output (units)
Cost of abnormal loss = Cost of normal output x Abnormal loss in units
Normal output in units
Or
=Total process cost - Scrap value of normal loss x Abnormal loss in units
Input in units – Normal loss in units
Abnormal gain: when the actual process loss is less than the normal loss or when the actual
output is more than the normal expected output, it gives rise to abnormal gain. It may arise
due to exceptionally good quality of materials, exceptionally high degree of efficiency on
the part of workers etc.
Abnormal gain in units = actual output (units) – normal output (units)
Value of abnormal gain = = Cost of normal output x Abnormal loss in units
Normal output in units
Or
= Total process cost-scrap value of normal loss x Abnormal gain in units
Input in units – Normal loss in units
To costing profit
and loss a/c
2. 10000 units have been issued to Process X at a cost of Rs.20000. the other expenses are
as follows:
Rs.
Materials 12,000
Labour 16,000
Factory 5,000
expenses
From past experience it is ascertained that wastage incurred in the process is 2% of input
and it realises Rs.50 per 100 units. The actual output of process is 9,800 units. Prepare
process X a/c and normal loss a/c.
3. In process A, 100 units of raw materials were introduced at a cost of Rs.1,000. the other
expenditure incurred by this process was Rs.600. of the units introduced 10% is normally
lost in the course of manufacturing and they possess a scrap value of Rs.3 each. The
output of process A was only 75 units. Prepare process A a/c and abnormal loss a/c.
5. The product of a company passes through 3 processes X, Y and Z. normal loss incurred
for each process is: X =2% Y =5% Z =10%
The loss has some scrap value. The scrap of process X and Y is sold at Rs.5 per 100
units and that of process Z at Rs.20 per 100 units. The following information is
additionally obtained:
X Y Z
Materials 6,000 4,000 2,000
Labour 8,000 6,000 3,000
Manufacturing 1,000 1,000 1,500
expenses
20,000 units have been issued to process X at a cost of Rs.10,000. the output of each
process has been as under.
Process X – 19,500 units Process Y – 18,800 units Process Z – 16,000 units
Prepare process accounts, finished stock a/c, normal loss , abnormal loss and gain a/c.
7. A product has to pass through 3 processes X, Y and Z. the normal wastage of the 3
processes are 2%, 5% and 10% respectively which are to be calculated on the number of
units that enter into each process. The scrap value of wastage of 3 processes is Rs.10,
Rs.40 and Rs. 20 per 100 units respectively. Following are the additional details.
X Y Z
Materials 12,000 4,000 4,000
Labour 8,000 6,000 6,000
Manufacturing 2,000 4,000 2,000
expenses
20,000 units were put into process X at a cost of Rs.16,000. the output of each process
has been: X = 19,600 units, Y = 18,400 units and Z = 16,700 units. Prepare process
accounts, normal loss a/c, abnormal loss a/c and abnormal gain a/c.
8. From the following figures, show the cost of 3 processes of manufacture. The product of
each process is passed on to the next process immediately on completion.
Process Process Process
A B C
9. The Bengal chemical com ltd produced three chemicals during the month of January
2017 by three consecutive processes. In each process, 2% of the total weight put in is lost
and 10% is scrap from which process 1 and 2 realises Rs.100 per tonne and from process
3 Rs.20 per tonne. The product of 3 processes is dealt with as follows:
Process 1 Process 2 Process 3
Raw material ₹ 120000 ₹ 28000 ₹ 107840
(1000 tons) (140 tons) (1348
tons)
Wages ₹ 20500 ₹ 18520 ₹15000
Overhead ₹ 10300 ₹ 7240 ₹ 3100
Passed to next process 75% 50%
Passed to warehouse for sale 25% 50% 100%
Prepare process accounts, showing the cost per tonne of each product.
10. On the basis of the following information, prepare process accounts and a statement of
profit
Process 1 Process 2 Process 3
Raw materials used 1000 tons - -
Cost per ton(Rs.) 200 - -
Manufacturing expenses(Rs.) 87500 34500 10710
Loss in weight 5% 10% 20%
Scrap(sales price Rs.50/ton) 50 ton 30 ton 51 ton
Sales price/ton(Rs.) 350 500 800
Management expenses were Rs.17500 and selling expenses were Rs.10000. of the
output of process 1 and of the output of process 2 are transferred to next process and
the balance are sold. The entire output of process 3 is sold.
11. The product of a chemical factory passes through two different processes. From past
experiences, it is ascertained that normal loss is: process A 2% process B 10%.The
scrap value in process A and B is Rs.25 and Rs.50 per 100 units respectively. 10000 units
of raw materials were introduced in process A in April at a cost of Rs.16000. the
following information is further available:
Process A Process B
Indirect materials(Rs.) 16000 5000
Direct labour(Rs.) 9000 8000
Direct expenses(Rs.) 8200 1500
Output in units 39000 36500
Finished stock in units
April 1 6000 5000
April 30 5000 8000
Value of stock/unit on 1st April(Rs.) 1.2 1.6
The stock is valued and transferred to next process at weighted average cost. Prepare
process cost accounts.
In some industries, two or more products are simultaneously produced in the same process.
Such products may be joint products, by products or co products.
Joint products
They refer to a group of individual products of significant relative sales value
simultaneously produced from the same raw materials. The basic features of joint products
are:
a. These products cannot be produced separately.
b. These are obtained from the common manufacturing process and common raw
materials.
c. These products carry almost equal economic importance or sales value.
d. They require further processing after the point of separation.
e. No product can be called as a main product.
Oil refining is the typical example of joint products. In the process of refining oil, joint
products such as kerosene, fuel oil, wax, tar etc. are obtained from crude petroleum. Other
examples are milk, butter, cream etc. obtained in dairies and copper, silver etc. obtained
from same ore.
According to ICMA, joint products are defined as “two or more products separated in the
course of processing, each having a sufficiently high saleable value to merit recognition as
a main products”.
By products
It is a secondary or subsidiary product which emerges as a result of manufacturing of the
main products. It is the residual material which is incidentally obtained from the production
of main products and has relatively small value. The basic features of by products are:
a. They are produced incidental to the main products.
b. Their value is very low compared to the main product.
c. They can be sold immediately after separation without further processing.
d. They emerge from the same basic raw materials.
e. They are produced simultaneously from a common process.
In case of sugar industry, the production of sugar is accompanied by bagasse and molasses.
Other examples include saw-dust, off-cuts etc. from wood working and sulphur, bitumen
etc. from oil refining process.
Co-products
They are those products that are produced together but not from the same materials and from
the same process. For example, in a bakery, bread, cakes, pastry and biscuits of various types
produced.
Joint products are comparatively of equal Their value is very low compared to the
importance. main products.
They should undergo further processing They can be sold immediately after
after separation before they are sold. separation.
Each joint product is a major product line. By products are incidental products with
negligible value.
From a joint process, products A, B and C are obtained, the joint cost being
Rs.150000. the units of the joint products were: A 3200, B 2500 and C 1800.
Apportion the joint costs among the products according to the average unit cost
method.
b. Physical unit method: The physical volume of materials found in the joint products at
the point of separation is taken as the basis of apportionment of joint costs. Any loss
arising during processing is also apportioned on the same basis.
A Dairy company produces the following products using 10000 litres of milk at
Rs.30/litre from a common process. Apportion the joint costs among the products
on the basis of physical unit method.
Kgs
Butter 7000
Cheese 2400
Cream 104
Ghess 96
c. Survey method (point value method): This method is on the presumption that joint costs
cannot be allocated satisfactorily by considering any one single factor. Therefore
management carries on extensive survey for collecting information of all factors involved
from the commencement of production to the final stage of sale. It may conduct survey on
volume, selling price, technical aspects etc. Here joint costs are apportioned on the basis of
the point value or percentages assigned to each product according to its relative importance.
In a timber industry three grades of timber namely A, B and C are obtained at split
off point of cutting operation at a cost of Rs.62000. The units of three grades
obtained are 600 units, 400 units and 200 units of A, B and C respectively. Technical
estimates show that weight of 6, 5 and 3 be assigned to each grade A, B and C
respectively. Show a statement showing apportionment of joint costs.
d. Contribution margin method: Joint costs are divided into variable cost and fixed cost. The
variable costs are apportioned over the joint products on the basis of the units produced.
Sales minus variable costs give the contribution ratio which is then used to apportion the
fixed costs.
Three products A, B and C are produced from a common process. The total cost up
to the split off point is Rs.23300- fixed cost Rs.3300 and variable costs
[Link] quantity of output produced and sold are 100kg, 60kg and 40kg of
A,B and C for Rs.140, Rs.130 and Rs.120 per kg. Apportion the joint cost among the
products A, B and C under contribution margin method.
e. Standard cost method: Joint cost is apportioned among joint products on the basis of
pre-determined standard cost for each joint product. This helps to compare the actual
with the standard and measures the efficiency.
f. Market value method: Under this method, the products are made to bear a proportion of
the joint cost on the basis of their ability to bear the same which depends upon the
expected market price of the [Link] is more scientific since the market price
necessarily depends upon the quality and grade of production. The market values vary on
the basis of point of valuation. Hence, the different methods under market value are:
1. Market value at the point of split off: When market value of each joint product is
known at the point of separation, the joint cost is apportioned in the proportion of these
values. The market value for the purpose may be either market value per unit or the
amount of market value of the entire units of each joint product.
From a joint process, 400 units of joint product X and 600 units of joint product Y
are obtained with market values of Rs.40/unit of X and Rs.20/unit of Y. the cost of
joint processing is Rs.21000. apportion the joint costs on the basis of selling price
and sales amount.
2. Market value after further processing: Application of this method is easy as the
selling price of each finished product will be readily available. From the sales value of
each joint product, the post-split off cost of respective product is deducted and on the
basis of values obtained, the joint cost is apportioned.
The joint cost of manufacturing 1000 units of A, 2000 units of B and 3000 units of C
is Rs.24000. The selling price of products A, B and C are Rs.5, Rs.4 and Rs.3
respectively. The product do not require any further processing costs after split-off
point. You are required to apportion the joint costs on sales price basis and on sales
value basis.
From a joint process, 500 units of product X, 300 units of Y and 200 units of product
Z are obtained which have market values of Rs.40, Rs.50 and Rs.30 per unit
respectively. The post-split off costs were Rs.5000 for X, Rs.500 for Y and Rs.1000
for Z. the joint costs amounted to Rs.18000. Apportion the joint costs among the
products.
g. Reverse cost method or net value method: Joint product costs are apportioned to
different products on the basis of the estimated cost at the separation point. The estimated
cost at the separation point is ascertained by deducting from the sales value of each joint
product, the estimated net profit, selling and distribution expenses if any and the
subsequent processing costs after separation.
1. A factory produces three products A, B and C which originates from a common process.
The actual joint costs are:
Material Rs.10200
Labour Rs. 11500
Overheads Rs.7500
A B C
Prepare a statement showing the apportionment of joint costs over different products.
2. The joint costs of three products X, Y and X are Material Rs.6000, Labour Rs.5000 and
Overhead Rs.4500 respectively. The subsequent expenses are as follows:
X Y Z
Prepare a statement showing the apportionment of joint costs over different products.
3. Joint cost of Products A, B and C are : Materials Rs.100000, Labour Rs.18000 and OH
Rs.8000 respectively. Compute share of joint costs based on the given data.
Additional Information
A B C
Sales value 100000 70000 60000
Estimated profit on sales 20% 30% 40%
Subsequent expenses 10000 9000 6000
Accounting for by-products
There are two methods for accounting by-products: Non-cost method and Cost method
Non-cost method (Sales value method): Costs are not assigned to by products but income
or revenue arising from the sale of by -product is credited to P and L A/c or to the Main
Product A/c. Following are the types of non-cost method:
a. Crediting the sales value of by product to other income (other income method): It is used
when the sales value of by-product is very small. Here sales value of by product is
treated as other income and credited to P & L A/c. If by product is not sold and is kept in
stock, its value for Balance sheet purpose shall be taken as nil.
b. By-product sales added to main product sales: Sales value of by-product is added to the
sales of the main product and profit or loss is computed by deducting the total cost from
the combined sales figures of main product and by product. By-product in hand, has no
value for Balance sheet purpose.
c. By-product value deducted from total cost: Sales value of by-product is deducted from
the total cost of the main product.
d. Selling and distribution expenses incurred for selling the by-product is deducted from
the sales value of the by-product and the net sales value is deducted from the total cost
of the main product.
e. Subsequent costs and the selling and distribution cost of the by-products are deducted
from the sales value of by-product and the net amount so arrived is deducted from the
total cost of the main product.
f. Reverse cost method: Net estimated cost of the by-product is calculated by deducting
from its sales value, the following:
- estimated profit on by-product,
- selling and distribution expenses of by product and
- costs incurred for further processing of by-product after the split-off point.
The estimated cost of the by-product is credited to the main product a/c to find out its cost.
1. The Kerala Chemical Ltd. Is engaged in the production of a Chemical X and in the
course of manufacturing, a by-product Y is produced, which after a separate process has
a commercial value. For the month of July 2016, the following are the summarised
costing data.
Joint expenses (Rs.) Separate expenses (Rs.)
X Y
Material 19200 7360 780
Labour 11700 7680 2642
Overhead 3450 1500 544
The output of the month was 143 tonnes of X and 49 tonnes of Y and the selling price of
Y is Rs.280/tonne. Assume that profit on Y is estimated at 50% of the selling price,
prepare an account showing the cost of X /tonne.
2. Prepare an account showing the cost per kg of the main product Alpha and by-product
Beta from the following.
Joint expenses (Rs.) Separate expenses (Rs.)
Alpha Beta
Material 10000 6000 500
Labour 7000 5000 2000
Overhead 2500 1500 600
Quantities produced during the period: Alpha - 100 kgs Beta – 50 kgs
The selling price of Beta was Rs.120/kg on which the profit earned was estimated at 30%.
3. In manufacturing the main product A, a company processes the resulting waste material
into two by product B1 and B2. Using revise costing method of by-products, prepare a
comparative profit and loss statement of 3 products from the following data.
Total joint cost up to separation point was Rs.68000
A B1 B2
Sales( all production) 164000 16000 24000
Cost after separation - 4800 7200
Estimated net profit % on sales - 20% 30%
Estimated selling expenses as % of sales value 20% 20% 20%
b. Standard cost method: By-products are valued at a standard rate determined for each
by product and credited to process account. The standard cost may be on technical
estimates or the average price over a period of time. The standard cost should be revised
now and then to give effect to change in actual cost.
c. Joint cost method: By-products are given due recognition and joint cost is apportioned
among joint products and by products using physical unit or market value method.
Equivalent production
1. In process X 1000 units were introduced. The normal loss was estimated @ 5% of
input. At the end of the month 230 units were incomplete. Finished units were 720.
The stage of completion is as follows: Calculate equivalent production units.
2. In process P 1000 units were introduced. The normal loss was estimated @ 10% of
input. At the end of the month 300 units were incomplete. Finished units were 550.
The stage of completion is as follows:
3. Input of materials – 10000 units. Normal loss was estimated @ 8% of input. Closing
WP was 900 units, material 70% complete and labour and overheads 30% complete.
8700 units were transferred to next process. Compute equivalent production.
4. The following data are available in respect of Process A for the month of April 2016.
Inter-process profits
In process costing, the usual practice is to transfer the output of each process to the next
process and from the last process to the finished stock account at actual cost price. But in
some of the manufacturing concerns, the transfer of output from one process to another and
from last process to finished stock account, is made at cost plus a certain percentage of
profit which is known as transfer price or inflated price. But it may create accounting
problem. Therefore, inter process profit included in the stock should be eliminated as this
profit is not yet realised. The cost of stock in each process and finished stock account shall
be calculated as follows:
The element of unrealised profit included in the value of stock shall be ascertained as
follows:
The amount of unrealised profit shall be debited to P&L A/c and credited to Reserve for
Unrealised Profit in order to ascertain the actual process profit. Thus the actual amount of
profit can be calculated as follows:
Actual profit = Apparent profit from process – Unrealised profit included in closing
stock
1. A product passes through two processes A and B, output of process A is transferred to
process B at cost plus 25% profit and the output of process B is similarly transferred to
finished stock account at cost plus 25% profit. The following information was further
available:
Process Process
A B
Materials 8000 24000
Wages 12000 16000
Closing 4000 12000
stock
( valued at
prime cost)
Out of the finished stock, a portion remained at hand valued at Rs.18000 and the
balance sold for Rs.58000. Prepare the process and finished stock account. Also
calculate the amount of reserve that should be made in respect of unrealised profit.
Sales during the period were Rs.900000. Prepare process accounts and finished stock
account
TRANSFER PRICING
Meaning
In decentralised organisations, very often goods/services which are output of one division
may be transferred to another division as input for better control. In such a case there is a
need to set a price for the goods/services sold or transferred. Such a price which applies
solely to transactions between divisions within an organisation is called a transfer price. In
other words, it is the price that one sub unit( segment, department, division and so on) of an
organisation that charges for a product/service supplied to another sub unit of the same
organisation as it is only an internal transfer and not sale. Transfer price becomes a cost to
the buying division and a revenue to the selling division.
1. Cost price
According to this method, goods and services are transferred from one segment of the
company to another on the basis of unit cost of production of the transferring division. The
cost could either be taken to be the actual cost of production or the standard cost of
production. The advantage of these methods of transfer pricing is that it is very simple and
convenient to operate. But, it distorts the profit of the various responsibility centres in the
sense that the profit of the transferring centre shall be underestimated and that of the centre
to which transfer is made would be overestimated. In fact, this method of transfer pricing is
inappropriate for profit centre analysis.
3. Incremental cost
Another method of transfer pricing in use by certain companies is the incremental cost of the
transferring division. Incremental cost can be computed in two ways depending upon the
circumstances. In case entire production is transferred to another division within the same
company, the increment cost will be the total of variable cost of transferring centre plus any
fixed costs which are directly attributable to that centre/division. The incremental cost so
calculated suffers from the same defects as that of cost price method. The second approach
may be used when goods and services are sold to outside customers as well as transferred
within the same company. In such a case, incremental cost may be taken as the opportunity
cost in the form of loss of revenue which the transferring division would have charged from
the outside customers. The second approach is similar to the market price basis and is more
useful for profit-centre analysis.
6. Standard price
Transfer prices can also be fixed on predetermined standard price basis. The standard price
may be determined on the basis of cost production and the prevailing market conditions.
Thus, division working at less than the desired efficiency will show lesser profits as
compared to the efficient division. However, difficulties may arise in fixing the standard
price agreeable to the different divisions.
7. Negotiated price
The intra-company transfer price can also be determined on the basis of negotiations
between the buying and the transferring division. Here determination of transfer price is
based on active participation, involvement, co-ordination and agreement of managers of
transferring and buying divisions. The price will be the mutually agreed price. Such as
pricing method will be advantages to both the divisions as well as the company as a whole.
However, this method could be used only when both the buying as well as transferring
divisions has alternative choice available with them.
Advantages:
- The buying division may purchase from outside sources, if the outside prices are lower than
internal division’s price.
- Buying and selling divisions are completely free to deal outside the company. This promotes
sub-unit autonomy and motivated managers.
- Managers can determine the appropriate transfer prices that satisfy the requirements of the
divisions and is in the best interest of the company as a whole.
Limitations:
- The agreed transfer price may depend on the negotiated skills and bargaining powers of the
managers involved. The final result may not be always optimal.
- Rather than agreement on transfer price, negotiations can lead to conflict between divisions
and may require top-management mediation.
- Negotiations are time-consuming for managers involved, when the number of transactions
and inter-dependencies are large.
8. Dual or Two-way Price
According to this method, the transferring division is allowed to give credit price, whereas,
the buying division is charged at a different price. It enables better evaluation of profit
centres and avoids conflicts among them on account of transfer prices. However, the total
profits of the various segments would differ from the actual profit of the company as a
whole. But, it poses no problems for the company as transfer prices are meant for internal
purposes of performance evaluation only.
Practical problems
1. A company fixes the inter-divisional transfer prices for its products on the basis of cost
plus an estimated return on investment in its divisions. The relevant portion of the
budget for the Division A for the year 2019-20 is given below.
Particulars Amount
Fixed assets 5,00,000
Current assets other than debtors 3,00,000
Debtors 2,00,000
Annual fixed cost for the division 8,00,000
Variable cost per unit of product 10
Budgeted volume of production per year (units) 4,00,000. Desired return on investment
28%. You are required to determine the transfer price for Division A.