Materials Cost Control in Manufacturing
Materials Cost Control in Manufacturing
2. Purchase order
After receiving requisition, the purchasing department places an order with a supplier. For
routine purchases, the order is placed with established suppliers. In other cases, the purchasing
department may ask from bids or send out request for price quotation before placing the order.
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Purchase order should clearly state the materials required and the price: and provide information
such as delivery period and the department for whom in the materials is purchased. Purchase
order may be prepared in several copies depending on the need of the firm. The original copy
however is sent to the supplier: Second copy to accounting department: third copy to store: and
so on.
While the PO process for your company may be unique in some ways, there are 7 elements of
the workflow that are common to most, if not all, purchase order processes:
1. Purchase order creation 4. Binding contract
2. Approval 5. Goods delivery
3. Dispatch 6. Three way match and 7. Closure
7 steps of the purchase order process
1. Order creation
The first step in the PO process is to create a purchase request. At this point, you’ll need to know
what is being purchased, the priority level of the requisition, your budget, when the product or
service is needed, who needs to approve the order, and the suppliers.
2. Approval
After the order has been created, the next step in the process is to get approval of the purchase
requisition. In some cases, this approval may be verbal or sent as an email. In other companies,
more formal actions, such as completing paperwork, may be required. The level of approvals
depends on the purchase amount, company policies or guidelines, and the requirements of the
supplier.
3. Dispatch
After the requisition is approved, the PO is sent to the selected vendors. The vendors then submit
bids based on the POs. The bids are approved based on price, quality, support, service, schedule,
and other factors relevant to your business.
4. Binding contract
After the bid is accepted, the company and the vendor must agree to a contract. The contract
typically includes terms and conditions relevant to the purchase, such as what support comes
with the item being purchased or how to handle any disputes.
5. Goods delivery
The supplier will then produce and deliver the items being purchased based on the outlined
schedule and shipping requirements. Your company will verify quality and match the goods
received against the expected goods. Typically, the supplier will send the purchasing company
an invoice that outlines the price and payment terms.
6. Three -way match
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After the goods received are approved, the purchasing company will then match the purchase
order with the PO and invoice from the supplier. Companies should check to ensure that all
charges are accurate.
7. Closure
After the three-way match is approved, the purchase order is closed out.
3. Receiving Materials
The receiving department performs the function of unloading and unpacking materials which are
received by an organization. Materials are inspected and inspection report is prepared, indicating
the items accepted and rejected, with reason. Receiving report is prepared by the receiving
department. Receiving report may be prepared in several copies, one going to each department
interested in the arrival of materials, including stories, purchasing department, and accounting
department.
4. Preparing and Recoding the Voucher:
After the receiving report is received, the purchasing unit compares the supplier's invoice with
the purchase order and receiving report to make sure that:
Goods ordered have been received in good condition and those listed on the invoice.
Terms, unit prices, shipping charges, and other details agree with order specifications.
Computations are correct.
Then the purchase of materials is recorded as follows:
Raw materials-----------------------------------------------xxx
Vouchers payable ---------------------------------------xxx
The above entry is recorded in a voucher register, and the voucher is sent to the treasurer’s office,
the voucher is filed in the unpaid vouchers file according to the last date on which the discount
may be taken.
5. Paying the voucher
A check is prepared for the net amount. The check is then recorded in the check register. The
employee marks the voucher “paid "by using a rubber stamp and enters the check is mailed to the
supplier, and the voucher is returned to the voucher clerk.
EOQ =
Were
√ 2 DC
H
EOQ =
√ 2 x 10,000 x 10
0.8
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2. Indirect labor: -is the wage of factory personnel who do not work directly on raw
materials. Indirect labor does not directly spend time on a particular job or product. The
distinction between direct labor and indirect labor is based on the convenience of linking
the time spent on a particular job or product. Although indirect workers spend time on
work of general nature, they also equally support production activities
2.2. [Link] of labor remuneration methods
The remuneration of employees is a reward of services rendered by him. It is an agreement
among employer and employee. For remuneration, B.K. Bhar has rightly point out that,
"Remuneration is the reward for labor and services, whereas incentive is the stimulation of
effort and effusiveness by offering monetary inducement or extra facilities."
A. Normal Remuneration Method
It has already been stated that labor is one of the main elements of production. The success of
a business organization is based on the efficiency of labor. There are several methods of
wage payment. These are differing from each organization to another organization. The
methods of wage payment are as follows:
1. Time Rate Method: This method is very popular method of payment of wages. Under
this method, the payment is made on the basis of time devoted by worker in the factory.
It is an oldest form of wage payment. In this method wages are calculated as follows:
Wages = Hours Worked x Rate per Hour
2. Piece Rate Method: In this method, wages are paid on the basis of units produced by
the workers. The rate of payment is determined by production department. Under this
method, wages of workers are calculated by following formula:
Total Wages = No. of Units Produced x Rate Per Unit
Illustration: From the following information, calculate total wages by piece rate method and
time rate method.
Standard Hours 60
Actual Hours Worked 50
No. of Unit Produced 500
Rate per Hour Br.20
Rate per unit produced Br.5
Solution:
The total wages paid to workers is calculated as follows:
Time Rate Method
Formula = Actual Hours Worked x Rate per Hour = 50 x Br. 20 = Br. 1,000
Piece Rate Method:
Formula = No. of Unit Produced X Rate per unit produced = 500XBr.5=2500
B. Incentive Wages Method
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Generally, incentive may be deemed as an extra payment paid by employer to
worker/employees for his additional efficiency. The main objective of an incentive plan to
induce a worker to produce more to earn higher wages. Incentive plans increase the
efficiency and capacity of workers
2.3. Accounting for Factory Over Head Costs
Overhead refers to any cost which is not directly attributable to a particular unit. In other
words, overheads are real costs and represent spending on resources or services which benefit
all units of products and services. Overhead costs are costs common to more than one unit
cannot be linked to a particular unit.
Factory overhead
Factory overhead is the aggregate of indirect costs associated with manufacturing activities,
Factory overhead is also called factory burden, manufacturing overhead, manufacturing
expresses, or indirect manufacturing costs.
Factory overhead includes:
Factory rent, lighting a heating
Depreciation repairs and maintenance
Salaries and related costs of production management
Wages of indirect costs of production management
Indirect materials and etc
In general, factory overhead costs are classified into three. There are:
1. Indirect labor
2. Indirect materials
3. Other factory overhead
In order to record the entry is:
Manufacturing overhead control -----------------------------xxx
Various accounts -----------------------------------------------xxx
Setting Overhead Rates
Manufacturing overhead costs are not directly traceable to a unit of output. Instead, these costs
are accumulated during the year and charged to jobs or products at the end of the year. However,
management cannot wait until the end of the year, or month to find out how much particular job
costs. Cost date are most useful when they are immediately available then they can be used to
evaluate efficiency, to suggest changes in procedures, and to help setting profitable selling
prices. The cost accountant is usually expected to report the total setting profitable selling prices.
The cost accountant is usually expected to report the total cost of a job as soon as its finished. At
this time the actual total overhead costs are available, as they would be the end of a fiscal
period. Thus, the accountant has to devise a method of estimating overhead costs applicable of
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the completed jobs. This is achieved by establishing a predetermined overhead rate, or
predetermined overhead application rate.
Predetermined overhead application rate refers to the rate determined before the commencement
of the period during which the same would be used.
Types of overhead rate bases
The overhead rate is calculated with reference to the amount of overhead provided in the budget
and a predetermined volume of production in terms of the base which will be used as
denominator. The base should be the best available of the cause-and-effect relationships
between overhead costs and cost drivers.
Overhead rate = Estimated manufacturing overhead during the year
Estimated activity base
Activity base may be any one of the six bases mentioned below:
1. Units of production 4. Prime cost
2. Direct material cost 5. Direct labor hours
3. Direct labor cost 6. Machine hours
Illustration
A summary of the budget data for Abdi manufacturer for the year ended December 31, 2019 is
given below:
Budgeted Manufacturing overhead costs during the year = $ 600,000
" Units of production = 30,000 units
" Direct labor costs = $400,000
" Direct labor hours = 240,000 hours
" Direct material costs = $ 360,000
" Machine hours = 350,000 hours
Required: Determine overhead application rate under each of the following bases:
a) Units of production
b) Direct material cost
c) Direct labor cost
d) Prime cost
e) Direct labor hours
f) Machine hours
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Units of production
Units of production result in a meaningful rate only if the manufacturing process is simple and
only if one type or a few very similar types of goods are produced.
Rate = Estimated Manufacturing Overhead
Estimated units of production
= 600,000 = $ 20 /unit
30,000
The rate implies that if one unit is produced, the overhead applied (charged) to this unit is $20.
If a job of 100 units is produced, the overhead applied to the job would be $2000 (i.e., $20 x
100 units= $2000)
b) Direct Material cost
Under this method, the overhead application rate is expressed as a percentage of direct material
costs. Rate = Estimated Manufacturing Overhead
Estimated Direct material costs
= 600,000
360,000
= 1.67 or 167% of direct maternal costs
If direct materials consumed of job No. 15 totaled $22,000, the overhead applied to this job
would be $36,740 (i.e 167%22000: 36,740)
Direct material cost is more appropriate when each article manufactured must require
approximately the same amount of materials, or usage must distribute uniformly thought out
the manufacturing process.
However, in practice, most overhead costs have little relationship to materials used. As a result,
it is likely to give totally inaccurate results.
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The direct labor hour basis is more appropriate if labor operations are the major part of the
production process.
Applying manufacturing overhead
In the preceding discussion, the methods of determining overhead application rate were
introduced. However, accounting for applied overhead was not introduced. Thus, this topic is
intended to introduce how manufacturing overhead is applied to jobs or products, how to record
in the accounting records, and how to treat the difference between actual manufacturing
overhead and applied manufacturing overhead.
In general, the following procedures are used to apply manufacturing overhead to jobs or
products.
Step 1. Select the application base (bases described earlier)
Step 2. Prepare a factory overhead budget for the planning period. The two key items are
(a) Budgeted total overhead and
(b) Budgeted total volume of the application base.
Step 3 Compute the overhead application rate by dividing the budgeted total overhead cost by
the budgeted total volume of the application base.
Step 4 Obtain the actual application base (such as machine hours) for the period.
Step5 Apply the overhead to the jobs by multiplying the overhead application rate by the actual
application base data.
Step 6 prepare the necessary entry to the applied factory overhead by the following entry
Work in process---------------------------xxx
Manufacturing applied -----------------------------xxx
Step 7 At the end of the period, account for any difference between the amount of overhead
actually incurred and overhead applied to products.
Example Suppose that a company budgeted its factory overhead for the fourth coming year
as $900,000. Assume that manufacturing overhead is applied to products on the basis of
machine hours of 600,000 hours. Assume further that a job cost sheet for job 243 included
the following information:
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under applied overhead. In other words, under applied overhead is said to exist if MOH
control account has debit balance.
Problems of overhead application
When FOH control Account is over Applied WIP, FG, and CGS as the same time increases but if
FOH control account is under applied it is vice versa. To eliminate the above problems there are
three types of adjustments.
The next question is how to treat under applied or over applied overhead. The treatment depends
on whether the objective is to prepare interim or annual financial statements. The manner of
treating under applied or over applied overhead varies, depending on whether the intention is for
interim or annual report
1. Monthly procedures (Interim Reporting)
The balance of MOH control account is closed to over “applied or under applied manufacturing
overhead” account at the end of the month.
Under applied overhead is closed as follows:
Under applied manufacturing overhead ………………. xxx
Manufacturing overhead control ………………………. xxx
Over applied overhead is closed as follows:
Manufacturing overhead control ………………… xxx
Over applied manufacturing overhead …………………… xxx
The under applied or over applied manufacturing overhead is not closed monthly. The amount
of under applied is considered a deferred charge and is shown under prepaid expenses on the
interim balance sheet as a deferred credit.
Note that the amount of under applied or over applied overhead does not appear in the interim
income statement. The statement of cost of goods manufactured shows direct materials used,
direct labor, and manufacturing overhead applied.
2. End-of-year procedures
The balance of under applied or over applied manufacturing overhead represents a difference
between overhead costs applied to goods worked on during the year and the actual overhead
costs that were incurred in producing these goods. There are two ways of treating under applied
or over applied overhead at the end of the year.
a) Immediate write off method
If the amount of under applied or over applied overhead is small, it is regarded as an adjustment
to Cost of Goods sold (i.e., written-off against cost of goods sold account).
Example
Assume that factory overhead incurred is $800.000 and that factory overhead applied is
$750.000. The difference is under applied of $50.000. The closing entry is:
Cost of Goods sold ……………………. 50.000
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Manufacturing overhead control ………50.000
If the difference were over applied, the closing entry would be:
Manufacturing overhead control ………… 50.000
Cost of Goods sold …………………………50.000
b) Perorations Method
If the amount of under applied or over applied overhead is considered to be material, it is divided
among Cost of Goods Sold. Work in Process, and Finished Goods Inventory.
Example Assume that factory overhead incurred is $900.000 and that factory overhead applied is
$1,200,000. The difference is considered to the material. Assume further that the ending
balances (before prorating) were as follows:
Cost of goods sold ………………….. $1,000,000
Work in Process …………………….. 400,000
Finished goods ……………………… 600,000
Required
1. Compute under applied or over applied overhead at year end.
2. Prorate under applied or over applied overhead among the three balances.
3. Prepare the closing entry to record the prorated amount assuming that applied overhead was
recorded in manufacturing overhead control account.
4. Compute the new balances of the account after proration.
Solution
1. Over applied overhead:
Factory overhead applied …………………………….. $1,200,000
Less Factory overhead incurred ………………………. 900.000
Over applied overhead ………………………………… $ 300.000
2. Proration of over applied overhead is shown below:
1,000,000 x 300,000
Cost of Goods Sold = = $ 150.000
2,000,000
400,000 x 300,000
Work in Process = = 60,000
2,000,000
600,000 x 300,000
Finished Goods = = 90,000
2,000,000
3. Manufacturing overhead control ……………… 300,000
Cost of Goods sold ……………………………… 150,000
Work in Process ………………………………… 60,000
Finished Goods …………………………………. 90,000
4. The balance of the three accounts after proration are computed below.
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Cost of Goods sold = 1,000,000 - $150,000 = $850,000
Work in Process = 400,000 - 60,000 = 340,000
Finished Goods = 600,000 - 90,000 = 510,000
2.4. Recording of costs and schedule of costs of products.
1. Recording of raw material purchase.
Raw material-------------------xx
Cash/account payable----------------xx
2. Recording of raw material used in to production.
Work-in-process inventory-----------------xx
Raw material------------------------------------xx
3. Recording of labor cost incurred in production.
Work-in-process inventory--------------------xx
Salary/ wage payable----------------------------xx
4. Recording of actual manufacturing overhead cost.
Manufacturing overhead cost----------xx
Various accounts -----------------------------xx
5. Recording of applied manufacturing overhead cost.
Work-in process inventory--------------xx
Manufacturing overhead applied ------------xx
6. Recording of completion of production.
Finished goods inventory----------------xx
Work in process inventory------------------xx
7. Recording sales of product.
Cash/account receivable----------------xx
Sales------------------------------------xx
Finished goods inventory--------------xx
Cost of goods sold expense----------------xx
Schedule of cost of goods manufactured
Alpha-Manufacturing company
Schedule of cost of Goods Manufactured
For the month of November, 20xx
Direct material used:
Raw-material inventory, November-1-------------------------xx
Add: November purchase of raw material---------------------xx
Raw material available for use----------------------------------xx
Deduct: Raw-material inventory, November-30---------------xx
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Raw material used--------------------------------------------------------------------------xx
Direct labor-----------------------------------------------------------------------------xx
Manufacturing overhead applied to work in process-----------------------------xx
Total manufacturing costs----------------------------------------------------------- xxx
Add: Work in process inventory, November-1-------------------------------------xx
Subtotal----------------------------------------------------------------------------------xx
Deduct: Work in process, November-30, -------------------------------------------xx
Cost of goods produced -------------------------------------------------------------------- xxx
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