Samcis - Ae212 - Module 7 Process Costing Lost Units
Samcis - Ae212 - Module 7 Process Costing Lost Units
Department of Accountancy
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AE 212: COST ACCOUNTING AND CONTROL
Week Topic Learning Outcomes Activities
MODULE 7:
PROCESS COSTING – INCREASE & LOST UNITS
In several manufacturing firms all materials that are needed to produce the product are
placed into process in the initial department. There are times however when additional materials
need to be added in the succeeding departments in order to complete the manufacture of a
product. The materials added can have two possible effects on the number of units as well as the
costs placed into process. These are:
1. The materials added will simply increase the unit cost, since these materials become part of the
finished product, however, the materials added do not necessarily increase the number of the
final units. An example is that of a car assembly plant, the additional parts that are added in a
succeeding department do not increase the number of cars being assembled.
2. The materials added will increase the number or volume of units, thereby causing a change in
the unit cost. In processing a chemical, water is often added to a mixture, causing an increase
in the number of units and a spreading of costs over a greater number of units. (Matz et.al, 1991)
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INCREASE IN UNITS
The additional materials in some production process can bring about an increase in the total
volume or number of units of the product. For example in the manufacture of shampoo, the
ingredients are often mixed in one department and water being added in a succeeding department.
The addition of the water increases the volume of liquid shampoo to be accounted for. Increasing
the quantity of liquid shampoo reduces the unit cost of prior department cost since the total prior
department’s cost will have to be allocated to a larger volume of product. This is true because the
increased quantity of liquid product absorbs the same total amount of the preceding department
cost.
Simple process cost problems with increase in units as a consequence of adding materials are
illustrated as follows:
FIFO
The Multiplicator Company produces its product in three departments. In Department 3, materials
added double the number of units. The following data pertain to operations of Department 3 in
March:
Units
Received from Department 2 10,000 units
Transferred to storeroom 16,000 units
In Process, end (100% complete as to materials, 50%
complete as to labor & overhead)
Costs
Transferred from Department 2 P 15,000
Added this department:
Materials P 4,400
Labor 4,500
Overhead 3,600
The Cost of Production Report for Department 3 of the Multiplicator Company is shown as follows:
Multiplicator Company
Cost of Production Report
For the Month Ended March 31, 2007
Department 3
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Units as accounted for 20,000
Equivalent Production 20,000 18,000
Note that the prior department’s (Department 2) cost has been adjusted and allocated to a larger
quantity, that is, P 15,000 being allocated to 20,000 units increase quantity arriving at a new revised
prior department’s unit cost at P0.75.
Thus:
Revised Unit Cost = Prior Department’s Cost
Increased Quantity
AVERAGE
Dumami Manufacturing Company manufactures its product in two departments. The addition
of materials at the start of the process in Department 2 increases the quantity by 5%. The following
data are on its March production:
Cost Data Units
Work in process, beg Work in process, beg - ½ done 3,000
Cost from Dep't 1 48,000.00 Received from Dep't 1 20,000
Cost this Dep't Work in process, end – 2/5 done 5,000
Materials 7,500.00
Labor 2,725.00
Overhead 2,000.00
Received from Dep't 1 335,400.00
Cost Added this month
Materials 29,100.00
Labor 20,900.00
Overhead 14,275.00
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Dumami Manufacturing Company
Cost of Production Report
For the Month Ended March 31, 201A
Department 2
Quantity Schedule:
WIP, beg 3,000
Received from Dep't 1 20,000
Increase in Units (5% x 20,000) 1,000
Total Units to be Accounted for 24,000
Work Work Conversion
Accounted for as follows: Actual Done Materials Done Cost
Finished and Transferred 19,000 100% 19,000 100% 19,000
WIP, end 5,000 100% 5,000 2/5 2,000
Units as Accounted For 24,000
Equivalent Production 24,000 21,000
Cost Analysis:
Cost from Preceding Dep't Units Total Cost Cost/u
WIP, beg 3,000 P 48,000 P 16.000
Received this Month 20,000 335,400 16.770
Increase in Units 1,000 - -
Total 24,000 P 383,400 P 15.975
Cost this Department WIP, beg This Month
Materials P 7,500 P 29,100 P 36,600 P 1.525
Labor 2,725 20,900 23,625 1.125
Overhead 2,000 14,275 16,275 0.775
Total P12,225 P 64,275 76,500 3.425
Total Cost to be Accounted For P459,900 P 19.400
LOST UNITS
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In the previous chapter, it is assumed that all units put into production were either finished or
unfinished with no units getting lost in the production process. This section of the chapter examines
the complications that arise when some units get lost in the production process.
Continuous processing can lead to the possibility of waste, shrinkage, and other possible factors
that can cause loss or spoilage of production units. Whether as a result of accidents, machine
malfunctions, poor workmanship, or substandard materials, it is to be expected that some portion of
the production process will have to be scrapped. To the extent that this spoilage is unavoidable is
properly included as one of the costs of obtaining good units of inventory. On the otherhand, spoilage
above and beyond the normal spoilage is treated as a loss. Thus one of our tasks in dealing with
spoilage will be to segregate normal from abnormal loss. Normal loss is defined as the average
spoilage necessary in the production process and will be included as an inventoriable cost. Being
inherent in the production process this loss is otherwise known as “unavoidable loss”. Thus, the cost of
normal loss is absorbed in the finished units as well as the units still in process. Abnormal loss is defined
as the spoilage in excess of average and will be treated as a period loss. (Moriarity, et.al. 1984) This
type of loss is otherwise known as “avoidable loss”. Thus abnormal loss is accounted for separately like
the way we account for finished units and units still in process.
In accounting for lost units, it is important to identify the stage of the manufacturing process
where the lost units occur.
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with those started during the period and is more popularly used compared to Method II which is
discussed below.
The procedure adopted by Method II is similar to that of Method I, its difference lies only in the
allocation of the cost absorbed by the lost units. In Method II the cost absorbed is allocated to the
remaining good units based on their stage of completion or in other words the equivalent production.
This is true because Method II assumes that the lost units are identified with both the beginning work
in process as well as units started during the period, hence remaining good units in this context include
opening work in process and started in process. The table on the next page summarizes Method I and
Method II.
Applicability Initial Succeeding Department
Method Department
Lost Units - Start Equivalent Production = zero Equivalent Production = 0
I & II of process Cost absorbed = zero Cost = prior department
Cost Allocated to =
Remaining Good Units
Lost Units – Equivalent Production = zero Equivalent Production = 0
I During the Cost absorbed = zero Cost = prior department
process Cost Allocated to =
Remaining Good Units
Lost Units – Equivalent Production = zero Equivalent Production = 0
II During the Cost absorbed = zero Cost = prior department
process Cost Allocated to =
Remaining Good Units
based on Stage of
Completion (Equivalent
Production)
It is to be emphasized at this stage that in most of the solutions to Philippine CPA examinations,
Method I is used. (Mejorada, 2002)
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Units:
Started in process 20,000 - -
Received from prior dept - 16,000 14,000
Units lost in process 1,000 1,000 1,000
In process, end 3,000 1,000 3,000
Stages of Completion 1/3 1/2 2/3
Costs:
Materials P 10,000 P 9,500 P 3,000
Labor 4,000 5,100 2,200
Manufacturing Overhead 3,000 4,000 2,000
Bokod Company
Cost of Production Report
For the Month Ended March 31, 2007
Department 1
Quantity Schedule:
Started in process 20,000 units
From the above Cost of Production Report, observe that the lost units found at the start of the
process have a zero equivalent production and since they occurred in the first department, the lost
units absorbed no costs at all.
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Bokod Company
Cost of Production Report
For the Month Ended March 31, 2007
Department 2
Quantity Schedule:
Received from Dept 1 16,000 units
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For purposes of illustration in Department 3, Method II is used.
Bokod Company
Cost of Production Report
For the Month Ended March 31, 2007
Department 3
Quantity Schedule:
Received from Dept 2 14,000 units
It is to be noted that the cost of the lost units were allocated to the remaining good units based
on their stage of completion or equivalent production.
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Units lost are not usually specifically identified for accounting purposes. They are simply classified
as either lost at the start, progressively during the process or at the end of the process. This is usually
done for simplicity. There are times however, when lost units are identified at specific points of
inspection. In which case, the equivalent production of the lost units will depend at the point when
inspection took place and its cost is then allocated to the good units that have passed the point of
inspection.
To illustrate this concept, consider this problem: Baguio Company uses process costing. All
materials are added at the beginning of the process. The produce is inspected when it is 80%
converted, and spoilage is identified only at that point. Normal spoilage is expected to be 5% of
good output. During July, 10,500 units were put into process. Current costs were P52,500 for materials;
P39,770 for labor; and P31,525 for factory overhead. The 3,000 units still in process at the end of July
were estimated to be 90% complete. All spoilage was normal. A total of 7,000 units were transferred
to finished goods. The cost of production report for Baguio Company in the month of July is as follows:
Baguio Company
Cost of Production Report
For the Month Ended July 31, 2011
Quantity Schedule:
Started in Process 10,500 units
Accounted for as follows: Actual Work Materials Work Done Labor &
Done Overhead
Finished and Transferred 7,000 100% 7,000 100% 7,000
In process, end 3,000 100% 3,000 90% 2,700
Normal lost units 500 100% 500 80% 400
Total units as accounted 10,500
Equivalent Production 10,500 10,100
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ABNORMAL LOSS: EQUIVALENT PRODUCTION AND COST
Abnormal loss refers to losses that are not expected to occur under efficient operating conditions
hence, abnormal loss is treated as period loss. Inefficient labor, defective materials are some
examples that can cause abnormal loss. Like normal loss, abnormal loss may also be discovered at
any point of the process, either, start, progressively during the process or end of the process Shown
on the next page is a summary of the equivalent production as well as cost absorbed by the abnormal
loss when discovered at the start, during or end of the production process.
Stage of
Process Initial Department Succeeding Department
START Equivalent Prod’n = zero Equivalent Prod’n = zero
Cost = zero Cost = Prior Department
DURING Equivalent Production = Stage of Equivalent Production = Stage of
Completion Completion
Cost = Cost this dept based on Cost = Prior Dept + Cost this dept. based
stage of completion on stage of completion
END Equivalent Production = 100% Equivalent Production = 100%
Cost = Cost this Department Cost = Prior Dept + Cost this dep’t
For purposes of illustrating the simultaneous occurrence of normal and abnormal loss in a given
situation when loss occurs in a succeeding department, consider the data pertaining to Alekssandra
Manufacturing with regards its operations in Department B for the month of July:
The Cost of Production Report for Department B for Alekssandra Company is as follows:
Alekssandra Manufacturing
Cost of Production Report
For the Month Ended July 31, 2007
Department B
Quantity Schedule
Received from Department A 25,000 units
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Equivalent Production 15,000
For the month of March, the cost data of the Apollo Manufacturing were as follows:
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Conversion costs 1/5 2/3 1/3
Required: Cost of production reports for Depts A, B and C.
Apollo Company
Cost of Production Report
For the Month Ended March 31, 201X
Department A
Quantity Schedule
Started in process 72,000 units
Accounted for as follows: Actual Work Materials Work Conversion
Done Done Cost
Finished & Transferred 60,000 100% 60,000 100% 60,000
In process, end 10,000 100% 10,000 1/5 2,000
Lost units, start 2,000 - - - -
Units accounted for 72,000
Equivalent Production 70,000 62,000
Apollo Company
Cost of Production Report
For the Month Ended March 31, 201X
Department B
Quantity Schedule
Received from Dept A 60,000
Increase in units 20,000
To be accounted for 80,000
Accounted for as follows: Actual Work Materials Work Conversion
Done Done Cost
Finished & Transferred 60,000 100% 60,000 100% 60,000
In process, end 15,000 100% 15,000 2/3 10,000
Lost units, start 5,000 - - - -
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Units accounted for 80,000
Equivalent Production 75,000 70,000
Apollo Company
Cost of Production Report
For the Month Ended March 31, 201X
Department C
Quantity Schedule
Received from Dept B 60,000
Increase in units 30,000
To be accounted for 90,000
Accounted for as follows: Actual Work Materials Work Conversion
Done Done Cost
Finished & Transferred 70,000 100% 60,000 100% 70,000
In process, end 15,000 100% 15,000 1/3 5,000
Lost units, start 5,000 - - - -
Units accounted for 90,000
Equivalent Production 85,000 75,000
Cost Analysis Total Cost Unit Cost
Materials P136,000 P 1.6000
Labor 60,000 0.8000
Overhead 15,000 0.2000
Total Factory cost P 211,000 P 2.6000
Add: Cost from Dept B 396,000 4.4000
Total cost to be accounted for P 607,000
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Adjustment for lost units:
(5,000 x P4.40 = P22,000 / 85,000 good units) 0.2588235
P7.2588235
EVAPORATION
For example, Evaporation Co. manufactures its product, Condensada, in two successive
departments, I and II. In Department II, the process takes 20 days, during which the product or units
in process suffer 10% evaporation proportionately with the process. During the month of March,
Department I transferred to Department II, 30,000 units at a cost of P60,000. Operations of Dept II for
the month follows:
Units: In process, March 1 975 (1/4)
Transferred to storeroom 25,200
In process, March 31 2,850
Costs: In process, March 1 P 2,000
Materials 39,200
Labor 25,000
Overhead 15,000
The following computations are necessary in the preparation of the cost of production report for
Evaporation Co., as follows:
• First, compute for the rate of evaporation:
Rate of evaporation per day = 10 % = .005 / day
20 days
• Computation of original quantities:
In process, beg – 975 units with ¼ stage of completion
Days in process = ¼ x 20 days = 5 days
Evaporation % = 5 days x .005/day = .025
Original volume is:
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975 = 1 – 0.025
975 / 0.975 = 1,000 (original volume)
Finished &Transferred: 25,200 units and has suffered 10% evaporation
Original volume = 25,200 / 90% = 28,000 units
Note: Of the 28,000 units, 1,000 originally came from beginning in process and 27,000 units coming
from units started in process.
Evaporation Co.
Cost of Production Report
For the Month Ended March 31, 201X
Department II
Quantity Schedule
Actual Net Work Equivalent
Done Production
In process, March 1 1,000
Received from Dep1t I 30,000
To be accounted for 31,000
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