question archive Nasir Manufacturing produces two products in its Sharjah plant: Crystal and Glass

Nasir Manufacturing produces two products in its Sharjah plant: Crystal and Glass

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Nasir Manufacturing produces two products in its Sharjah plant: Crystal and Glass. Since inception, Nasir has used only one manufacturing overhead pool to accumulate costs. Manufacturing overhead has been allocated to products based on direct labor hours.

Until recently, Nasir was the sole producer of Glass and was able to dictate the selling price. However, last year Zayed Products began marketing a comparable product at a price below the standards costs developed by Nasir. Market share has declined rapidly, and Nasir must decide whether to meet the competitive price or to discontinue the product line. Recognizing that discontinuing the product line would place additional burden on its remaining product, Crystal.

Nasir is planning to use the activity-based costing (ABC) to determine if it would show a different cost structure for the two products.

The three major indirect costs for manufacturing the products are purchase orders, power usage and setup costs and handling materials. A decision was made to separate the manufacturing department costs into three activity centers: 1) Inspection using number of purchase orders as the cost driver, 2) Fabricating using machine hours as the cost driver and 3) Assembly using number of setups as the cost driver.

The annual budget before separation of manufacturing overhead is shown below in the table:

 

Total Cost

Product line

Crystal

Class

Number of units

 

   60,000

80,000

Direct labor

 

3 hours/unit

4 hours/unit

Number of direct labor hours

          240,000 hours

   

Total Direct Labor

       AED 870,000

   

Direct Material

 

AED 7/unit

AED 8/unit

Manufacturing Overhead

       AED   660,000

   

The cost structure after separation of overhead into activity pools is shown below:

 

Inspection

Fabricating

Assembly

Direct Labor

25%

35%

40%

Direct Material

20%

30%

50%

Manufacturing overhead

35%

25%

40%

The activity base rates for the products are shown below:

Activity Base

Crystal

Glass

Number of Purchase Orders

5,000

6,000

Machine hours per unit

6

8.76

Number of setups

7,000

9,000

Questions:

  1. By allocating the manufacturing overhead based on direct labor hours, calculate the:
  1. Total manufacturing budgeted cost of the manufacturing department 
  2. Cost per unit for Crystal product 
  3. Cost per unit for Class product 
  1. Using ABC system , calculate the cost per unit for:
  1. Crystal
  2. Glass 
  1. Discuss how a decision by Nasir Manufacturing regarding the continued production of Crystal will be affected by the results of your calculations in requirement C. 

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Answer:

1)              
By allocating the manufacturing overhead based on direct labor hours, calculate the:          
Total manufacturing budgeted cost of the manufacturing department            
Predetermined overhead rate = budgeted overhead ÷ budgeted direct-labor hours              
Predetermined overhead rate = AED 660,000/ 240,000 DLH                                2.75 per direct labor hour        
Direct-labor rate = AED 870,000 / 240,000 DLH                                3.63 per direct labor hour        
               
Cost per unit for Crystal product:              
Direct Material (Given) AED 7.00            
Direct labor ($3.63  per hour × 3 hours) AED 10.88            
Overhead ($2.75 per hour  × 3 hours) AED 8.25            
Cost per unit for Crystal product AED 26.13            
               
Cost per unit for glass product :              
Direct Material (Given) AED 8.00            
Direct labor ($3.63  per hour × 4 hours) AED 14.50            
Overhead ($2.75 per hour  × 4 hours) AED 11.00            
Cost per unit for glass product AED 33.50            
               
2)              
  Total Cost Inspection Fabricating Assembly Inspection Fabricating Assembly
Direct Labor AED 870,000 25% 35% 40% AED 217,500 AED 304,500 AED 348,000
Direct Material (60,000 x 7)+ (80,000 x 8) AED 1,060,000 20% 30% 50% AED 212,000 AED 318,000 AED 530,000
Manufacturing overhead AED 660,000 35% 25% 40% AED 231,000 AED 165,000 AED 264,000
Total Cost         AED 660,500 AED 787,500 AED 1,142,000
  Total Manufacturing overhead Total activity Cost per unit      
Inspection AED 231,000 11,000 orders AED 21.00 per order    
Fabricating AED 165,000 1,060,800 machine hours per units AED 0.16 per unit    
Assembly AED 264,000 16,000 setups AED 16.50 per setups    
               
Cost per unit for Crystal product:              
Direct Material (Given) AED 7.00            
Direct labor ($3.63  per hour × 3 hours) AED 10.88            
Inspection (AED 21 x 5000)/60000 units AED 1.75            
Fabricating AED 0.16            
Assembly (AED 16.50  x 7000/60000 units AED 1.93            
Cost per unit for Crystal product under ABC AED 21.71            
               
Cost per unit for glass product :              
Direct Material (Given) AED 8.00            
Direct labor ($3.63  per hour × 4 hours) AED 14.50            
Inspection (AED 21 x 6000)/80000 units AED 1.58            
Fabricating AED 0.16            
Assembly (AED 16.50  x 9000/80000 units AED 1.86            
Cost per unit for glass product  under ABC AED 26.09            
               
3)              
Glass unit cost:              
Cost with overhead assigned on direct-labor hours AED 33.50            
Cost using activity-based costing AED 26.09            
The activity-based costing unit costs may lead the company to decide to lower its price for Glass in order to be more competitive in the market and continue production of the product. It now appears that Glass has lower unit costs and can afford lower prices. Using ABC for determining overhead costs generally leads to a more accurate estimate of the costs incurred to produce a product. Management should be able to make better informed decisions regarding pricing and production of the company’s products.              

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