question archive 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:
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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