2
Materials
BASIC CONCEPTS AND FORMULAE
1.
Maximum Level: It indicates the maximum figure of inventory quantity held in stock
at any time.
2.
Minimum Level: It indicates the lowest figure of inventory balance, which must be
maintained in hand at all times, so that there is no stoppage of production due to
non-availability of inventory.
3.
Re-order level: This level lies between minimum and the maximum levels in such a
way that before the material ordered is received into the stores, there is sufficient
quantity on hand to cover both normal and abnormal consumption situations.
4.
Danger level: It is the level at which normal issues of the raw material inventory are
stopped and emergency issues are only made.
5.
ABC Analysis: It is a system of inventory control. It exercises discriminating control
over different items of stores classified on the basis of the investment involved. Items
are classified into the following categories:
A Category: Quantity less than 10 % but value more than 70 %
B Category; Quantity less than 20 % but value about 20 %
C Category: Quantity about 70 % but value less than 10%
6.
Two bin system: Under this system each bin is divided into two parts - one, smaller
part, should stock the quantity equal to the minimum stock or even the re-ordering
level, and the other to keep the remaining quantity. Issues are made out of the larger
part; but as soon as it becomes necessary to use quantity out of the smaller part of
the bin, fresh order is placed.
7.
System of budgets: The exact quantity of various types of inventories and the time
when they would be required can be known by studying carefully production plans
and production schedules. Based on this, inventories requirement budget can be
prepared. Such a budget will discourage the unnecessary investment in inventories.
8.
Perpetual inventory: Perpetual inventory represents a system of records maintained by
the stores department. It in fact comprises: (i) Bin Cards, and (ii) Stores Ledger.
© The Institute of Chartered Accountants of India
2.2
9.
Cost Accounting
Continuous stock verification: Continuous stock taking means the physical checking of
those records (which are maintained under perpetual inventory) with actual stock.
10. Economic Order Quantity (EOQ): It is the calculation of optimum level quantity
which minimizes the total cost of Ordering and Delivery Cost and Carrying Cost.
11. Review of slow and non-moving items: Disposing of as early as possible slow
moving items, in return with items needed for production to avoid unnecessary
blockage of resources.
12. Input output ratio: Inventory control can also be exercised by the use of input
output ratio analysis. Input-output ratio is the ratio of the quantity of input of material
to production and the standard material content of the actual output.
13. Inventory turnover ratio: Computation of inventory turnover ratios for different
items of material and comparison of the turnover rates provides a useful guidance for
measuring inventory performance. High inventory turnover ratio indicates that the
material in the question is a fast moving one. A low turnover ratio indicates overinvestment and locking up of the working capital in inventories
14. Valuation of Material Issues: Several methods of pricing material issues have been
evolved which are as follows:
a)
First-in First-out method: The materials received first are to be issued first
when material requisition is received. Materials left as closing stock will be at
the price of latest purchases.
b)
Last-in First-out method: The materials purchased last are to be issued first
when material requisition is received. Closing stock is valued at the oldest stock
price.
c)
Simple Average Method:
Material Issue Price =
d)
Total of unit price of each purchase
Total Numbers of purchases
Weighted Average Price Method: This method gives due weightage to
quantities purchased and the purchase price to determine the issue price.
Weighted Average Price =
Total cost of Materials received
Total Quantity purchases
15. Various Material Losses
a)
Wastage: Portion of basic raw material lost in processing having no
recoverable value
b)
Scrap: The incidental material residue coming out of certain manufacturing
operations having low recoverable value.
© The Institute of Chartered Accountants of India
Materials
2.3
c)
Spoilage: Goods damaged beyond rectification to be sold without further
processing.
d)
Defectives: Goods which can be rectified and turned out as good units by the
application of additional labour or other services.
Basic Formulas
1.
Maximum Level = Reorder Level + Reordering Quantity – Minimum Consumption
during
the period required to obtain delivery.
Or
RL + RQ – MnC
Or
Safety Stock + EOQ
2.
Minimum Level
=
Reorder Level – (Normal usage per period × Average
delivery time)
3.
Average Stock Level =
Maximum Level + Minimum Level
2
Minimum Level + ½ Reorder Quantity
4.
Reorder Level =
Maximum Reorder period × Maximum Usage
=
Normal Usage × (Minimum Stock Period + Average Delivery
=
Safety Stock + Lead Time Consumption
Time)
5.
Danger Level =
Minimum Consumption × Emergency Delivery Time
6.
EOQ =
7.
Ordering Cost =
Annual usage × Fixed Cost per Order
Quantity Ordered
8.
Carrying Cost =
Quantity ordered
× Purchase Price for Inventory × Carrying
2
2 × Annual Consumption × Buying cos t per order
Cost of carrying one unit of inventory for one year
Cost
inventory
9.
Inventory Turnover Ratio =
expressed as % of average
Material Consumed
Average Inventory
© The Institute of Chartered Accountants of India
2.4
Cost Accounting
10. Inventory Turnover Period = 365 ÷ Inventory Turnover Ratio
11. To decide whether discount on purchase of material should be availed or not,
compare total inventory cost before discount and after discount. Total inventory cost
will include ordering cost, carrying cost and purchase cost.
12. Safety Stock =
Annual Demand
× (Max. lead time – Normal / Average lead time)
365
13. Total Inventory Cost = Ordering Cost + Carrying Cost + Purchase Cost
Note: For calculation of total inventory carrying cost, average inventory should be taken
as half of EOQ. Average inventory cost is normally given as a percentage of cost per unit
Question 1
How normal and abnormal loss of material arising during storage treated in Cost Accounts?
Answer
Cost Accounts treatment of normal and abnormal loss of material arising during
storage.
The difference between the book balance and actual physical stock, which may either be gain
or loss, should be transferred to Inventory Adjustment Account pending scrutiny to ascertain
the reason for the difference.
If on scrutiny, the difference arrived at is considered as normal, then such a difference should
be transferred to overhead control account and if abnormal, it should be debited to costing
profit and loss account.
In the case of normal losses, an alternative method may be used. Under this method the price
of the material issued to production may be inflated so as to cover the normal loss.
Question 2
Distinguish clearly Bincards and Sores Ledger.
Answer
Both bin cards and stores ledger are perpetual inventory records. None of them is a substitute
for the other. These two records may be distinguished from the following points of view:
(i)
Bin card is maintained by the store keeper, while the stores ledger is maintained by the
cost accounting department.
(ii)
Bin card is the stores recording document whereas the stores ledger is an accounting
record.
© The Institute of Chartered Accountants of India
Materials
2.5
(iii) Bin card contains information with regard to quantities i.e. their receipt, issue and
balance while the stores ledger contains both quantitative and value information in
respect of their receipts, issue and balance.
(iv) In the bin card entries are made at the time when transaction takes place. But in the
stores ledger entries are made only after the transaction has taken place.
(v) Inter departmental transfer of materials appear only in stores ledger.
(vi) Bin cards record each transaction but stores ledger records the same information in a
summarized form.
Question 3
What is Just in Time (JIT) purchases? What are the advantages of such purchases?
Answer
Just in time (JIT) purchases means the purchase of goods or materials such that delivery
immediately precedes their use.
Advantages of JIT purchases:
Main advantages of JIT purchases are as follows:
1.
The suppliers of goods or materials co-operates with the company and supply requisite
quantity of goods or materials for which order is placed before the start of production.
2.
JIT purchases results in cost savings for example, the costs of stock out, inventory
carrying, materials handling and breakage are reduced.
3.
Due to frequent purchases of raw materials, its issue price is likely to be very close to the
replacement price. Consequently the method of pricing to be followed for valuing material
issues becomes less important for companies using JIT purchasing.
4.
JIT purchasing are now attempting to extend daily deliveries to as many areas as
possible so that the goods spend less time in warehouses or on store shelves before
they are exhausted.
Question 4
Discuss the accounting treatment of defectives in cost accounts
Answer
Accounting treatment of defectives in cost accounts:
Defectives refers to those units or portions of production, which do not meet the prescribed
specifications. Such units can be reworked or re-conditioned by the use of additional material,
labour and /or processing and brought to the point of either standard or sub-standard units.
The possible way of treating defectives in cost accounts are as below:
© The Institute of Chartered Accountants of India
2.6
1.
Cost Accounting
When defectives are normal and it is not beneficial to identity them job-wise, then the
following methods may be used.
(a) Charged to good products: The cost of rectification of normal defectives is charged to
good units. This method is used when defectives rectified are normal.
(b) Charged to general overheads. If the department responsible for defectives cannot be
identified, the rework costs are charged to general overheads.
(c)
Charged to departmental overheads: If the department responsible for defectives can be
correctly identified, the rectification costs should be charged to that department.
2.
When normal defectives are easily identifiable with specific job the rework costs are
debited to the identified job.
3.
When defectives are abnormal and are due to causes within the control of the
organisation, the rework cost should be charged to the Costing Profit and Loss Account.
Question 5
Explain the concept of "ABC Analysis" as a technique of inventory control
Answer
ABC Analysis: It is a system of selective inventory control whereby the measure of control
over an item of inventory varies with its usage value. It exercises discriminatory control over
different items of stores grouped on the basis of the investment involved,. Usually the items of
material are grouped into three categories viz; A, B and C according to their use value during
a period. In other words, the high use value items are controlled more closely than the items of
low use value.
(i)
'A' Category of items consists of only a small percentage i.e., about 10 % of the total
items of material handled by the stores but require heavy investment i.e., about 70% of
inventory value, because of their high prices and heavy requirement.
(ii)
'B' Category of items comprises of about 20% of the total items of material handled by
stores. The percentage of investment required is about 20% of the total investment in
inventories.
(iii) 'C category of items does not require much investment. It may be about 10% of total
inventory value but they are nearly 70% of the total items handled by stores.
'A' category of items can be controlled effectively by using a regular system, which ensures
neither over- stocking nor shortage of materials for production. Such a system plans its total
material requirements by making budgets. The stocks of materials are controlled by fixing
certain levels like maximum level, minimum level and re-order level. A reduction in inventory
management costs is achieved by determining economic order quantities after taking into
account ordering cost and carrying cost. To avoid shortages and to minimize heavy
© The Institute of Chartered Accountants of India
Materials
2.7
investment of funds in inventories, the techniques of value analysis, variety reduction,
standardization etc. are used along with aforesaid techniques.
In the case of 'B' category of items, as the sum involved is moderate, therefore, the same
degree of control as applied in 'A' category of items is not warranted. The order for the items,
belonging to this category may be placed after reviewing their situation periodically. This
category of items can be controlled by routine control measures.
For 'C' category of items, there is no need of exercising constant control. Orders for items in
this group may be placed either after six months or once in a year, after ascertaining
consumption requirements.
Question 6
Distinguish between Re-order level and Re-order quantity
Answer
Re-order level & Re-order quantity: Re-order level is defined as that level of an inventory item
where a fresh order for its replenishment is placed. Mathematically it can be determined by
using the following formulas:
Re-order level (ROL)
= [Maximum consumption x Maximum re-order period]
Alternatively:
Average
⎛ Average rate of
⎞
⎟
= Minimum level + ⎜⎜
×
re − order period ⎟⎠
⎝ consumption
Re-order quantity (ROQ) is defined as that quantity of an inventory item for which order is
placed again and again. Economic order quantity is a re-order quantity but not vice-a-versa. It
can be determined by using the following mathematical expression:
EOQ = ROQ =
2 × Annual requirement of inventory item in units × Ordering cos t per order
Annual carrying cos t per unit per annum
Question 7
How is slow moving and non-moving item of stores detected and what steps are necessary to
reduce such stocks?
Answer
Detection of slow moving and non-moving item of stores:
The existence of slow moving and non-moving item of stores can be detected in the following
ways.
(i)
By preparing and scanning periodic reports showing the status of different items or
stores.
© The Institute of Chartered Accountants of India
2.8
(ii)
Cost Accounting
By calculating the stock holding of various items in terms of number of days/ months of
consumption.
(iii) By computing ratios periodically, relating to the issues as a percentage of average stock
held.
(iv) By implementing the use of a well designed information system.
Necessary steps to reduce stock of slow moving and non-moving item of stores:
(i)
Proper procedure and guidelines should be laid down for the disposal of non-moving
items, before they further deteriorates in value.
(ii)
Diversify production to use up such materials.
(iii) Use these materials as substitute, in place of other materials.
Question 8
Explain the advantages that would accrue in
Using the LIFO method of pricing for the valuation of raw material stock
Answer
LIFO- Last-in-first-out: A method of pricing for the valuation of raw material stock. It is based
on the assumption that the items of the last batch(lot) purchased are the first to be issued.
Therefore, under this method, the price of the last batch(lot) of raw material is used for pricing
raw material issues until it is exhausted. If, however, the quantity of raw material issued is
more than the quantity of the latest lot, the price of the last but one lot and so on will be taken
for pricing the raw material issues.
The advantages that would accrue from the use of LIFO method of pricing the valuation of raw
materials, are as follows:(i)
The cost of materials used is nearer to the current market price. Thus the cost of goods
produced depends upon the trend of the market price of materials. This enables the
matching of cost of production with current sales revenues.
(ii)
Use of LIFO during the period of rising prices does not depict unnecessarily high profit in
the income statement; compared to the first-in-first-out or average methods. The profit
shown by the use of LIFO is relatively lower, because the cost of production takes into
account the rising trend of material prices.
(iii) When price of materials fall, the use of LIFO method accounts for rising the profits due to
lower material cost. In spite of this finished product appears to be more competitive and
at market prices.
(iv) Over a period, the use of LIFO will iron out the fluctuations in profit.
(v) During inflationary period, the use of LIFO will show the correct profit and thus avoid
paying unduly high taxes to some extent.
© The Institute of Chartered Accountants of India
Materials
2.9
Question 9
(a) Discuss briefly the considerations governing the fixation of the maximum and minimum
levels of inventory.
(b) A company uses three raw materials A, B and C for a particular product for which the
following data apply :–
Raw
Material
A
B
C
Usage
Reper unit
order
of
Quantity
product
(Kgs)
(Kgs)
10
10,000
4
5,000
6
10,000
Price
per
Kg.
Delivery period
(in weeks)
Minimum Average Maximum
(`)
0.10
0.30
0.15
1
3
2
2
4
3
3
5
4
Reorder
level
(Kgs)
Minimum
level
(Kgs)
8,000
4,750
2.000
Weekly production varies from 175 to 225 units, averaging 200 units of the said product.
What would be the following quantities:–
(i)
Minimum Stock of A?
(ii)
Maximum Stock of B?
(iii) Re-order level of C?
(iv) Average stock level of A?
Answer
(a) Considerations for the fixation of maximum level of inventory.
Maximum level of an inventory item is its maximum quantity held in stock at any time.
The mathematical formula used for its determination is as follows:
Maximum level = Re-order level – (Minimum Consumption × Minimum Re-order period) +
Re-order quantity.
The important considerations which should govern the fixation of maximum level for
various inventory items are as follows:
(1) The fixation of maximum level of an inventory item requires information about reorder level. The re-order level itself depends upon its maximum rate of consumption
and maximum delivery period. It in fact is the product of maximum consumption of
inventory item and its maximum delivery period.
(2) Knowledge about minimum consumption and minimum delivery period for each
inventory item should also be known.
© The Institute of Chartered Accountants of India
2.10
Cost Accounting
(3) The determination of maximum level also requires the figure of economic order
quantity. Economic order quantity means the quantity of inventory to be ordered so
that total ordering and storage cost is minimum.
(4) Availability of funds, storage capacity, nature of items and their price also are
important for the fixation of minimum level.
(5) In the case of important materials due to their irregular supply, the maximum level
should be high.
Considerations for the fixation of minimum level of inventory
Minimum level indicates the lowest figures of inventory balance, which must be
maintained in hand at all times, so that there is no stoppage of production due to nonavailability of inventory. The formula used for its calculation is as follows:
Minimum level of inventory = Re-order level – (Average rate of consumption × Average
time of inventory delivery).
The main considerations for the fixation of minimum level of inventory are as
follows:
1.
Information about maximum consumption and maximum delivery period in respect
of each item to determine its re-order level.
2.
Average rate of consumption for each inventory item.
3.
Average delivery period for each item. The period can be calculated by averaging
the maximum and minimum period.
(b) (i)
Minimum stock of A
Re-order level – (Average rate of consumption × Average time required to obtain
fresh delivery)
=
8,000 – (2,000 × 2) = 4,000 kgs.
(ii) Maximum stock of B
Re-order level – (Minimum Consumption × Minimum Re-order period) + Re-order
quantity
=
4,750 – (4 × 175 × 3) + 5,000
=
9,750 × 2,100 = 7,650 kgs.
(iii) Re-order level of C
Maximum re-order period × Maximum Usage
=
4 × 1,350 = 5,400 kgs.
OR
© The Institute of Chartered Accountants of India
Materials
2.11
Re-order level of C
=
Minimum stock of C+(Average rate of consumption × Average time required to
obtain fresh delivery)
=
2,000 + [(200×6)×3] kgs. = 5,600 kgs.
(iv) Average stock level of A
=
Minimum stock level of A + 21 Re-order quantity
=
4,000 + 21 10,000 = 4,000 + 5,000 = 9,000 kgs.
OR
Average Stock level of A
=
Minimum stock + Maximum stock
(Refer to working note)
2
=
4,000 + 16,250
= 10,125 kgs.
2
Working note
Maximum stock of A = ROL + ROQ – (Minimum consumption × Minimum re-order period)
=
8,000 kgs + 10,000 – [(175×10)×1] = 16,250 kgs.
Question 10
A company has the option to procure a particular material from two sources:
Source I assures that defectives will not be more than 2% of supplied quantity.
Source II does not give any assurance, but on the basis of past experience of supplies
received from it, it is observed that defective percentage is 2.8%.
The material is supplied in lots of 1,000 units. Source II supplies the lot at a price, which is
lower by ` 100 as compared to Source I. The defective units of material can be rectified for
use at a cost of ` 5 per unit.
You are required to find out which of the two sources is more economical
Answer
Comparative Statement of procuring material from two sources
Defective (in %)
© The Institute of Chartered Accountants of India
Material source
I
Material source
II
2
2.8
2.12
Cost Accounting
(Future estimate)
(Past experience)
1,000
1,000
20
28
(1,000 units×2%)
(1,000 units ×2.8%)
Additional price paid per lot (`) (A)
100
–
Rectification cost of defect (`) (B)
100
140
(20 units ` 5)
(28 units × ` 5)
200
140
Units supplied (in one lot)
Total defective units in a lot
Total additional cost per lot (`): [(A)+(B)]
Decision: On comparing the total additional cost incurred per lot of 1,000 units, we observe that it
is more economical, if the required material units are procured from material source II.
Question 11
What is material handling cost? How will you deal it in cost account?
Answer
Material handling cost: It refers to the expenses involved in receiving, storing, issuing and
handling materials. To deal with this cost in cost accounts there are two prevalent approaches
as under:
First approach suggests the inclusion of these costs as part of the cost of materials by
establishing a separate material handling rate e.g., at the rate of percentage of the cost of
material issued or by using a separate material handling rate which may be established on the
basis of weight of materials issued.
Under another approach these costs may be included along with those of manufacturing
overhead and be charged over the products on the basis of direct labour or machine hours.
Question 12
At the time of physical stock taking, it was found that actual stock level was different from the
clerical or computer records. What can be possible reasons for such differences? How will you
deal with such differences?
Answer
Possible reasons for differences arising at the time of physical stock taking may be as follows when
it was found that actual stock level was different from that of the clerical or computer records:
(i)
Wrong entry might have been made in stores ledger account or bin card,
(ii)
The items of materials might have been placed in the wrong physical location in the
store,
© The Institute of Chartered Accountants of India
Materials
2.13
(iii) Arithmetical errors might have been made while calculating the stores balances on the
bin cards or store-ledger when a manual system is operated,
(iv) Theft of stock.
When a discrepancy is found at the time of stock taking, the individual stores ledger account
and the bin card must be adjusted so that they are in agreement with the actual stock. For
example, if the actual stock is less than the clerical or computer record the quantity and value
of the appropriate store ledger account and bin card (quantity only) must be reduced and the
difference in cost be charged to a factory overhead account for stores losses.
Question 13
RST Limited has received an offer of quantity discount on its order of materials as under:
Price per tonne
Tonnes number
` 9,600
` 9,360
` 9,120
` 8,880
` 8,640
Less than 50
50 and less than 100
100 and less than 200
200 and less than 300
300 and above
The annual requirement for the material is 500 tonnes. The ordering cost per order is ` 12,500
and the stock holding cost is estimated at 25% of the material cost per annum.
Required
(i)
Compute the most economical purchase level.
(ii)
Compute EOQ if there are no quantity discounts and the price per tonne is ` 10,500.
Answer
(i)
Order
size (Q)
(Units)
No. of
Cost of
orders purchase Ax
A/Q (Units) per unit cost
Carrying cost
A
×`12500
Q
Carrying cost
Q
×C×25%
2
Total cost
(3+4+5)
(1)
(2)
(3)
(4)
(5)
(6)
40
12.5
48,00,000
1,56,250
48,000
50,04,250
(500×9600)
© The Institute of Chartered Accountants of India
⎛ 40
⎞
⎜ × 9600 × 0.25 ⎟
2
⎝
⎠
2.14
Cost Accounting
50
10
46,80,000
1,25,000
(500×9360)
100
5
45,60,000
⎛ 50
⎞
⎜ × 9360 × 0.25 ⎟
⎝ 2
⎠
62,500
(500×9120)
200
2.5
44,40,000
1.67
43,20,000
47,36,500
1,14,000
⎛ 100
⎞
× 9120 × 0.25 ⎟
⎜
⎝ 2
⎠
31,250
(500×8880)
300
48,63,500
58,500
46,93,250
2,22,000
⎛ 200
⎞
× 8880 × 0.25 ⎟
⎜
2
⎝
⎠
20,875
3,24,000
46,64,875
(500×8640)
⎛ 300
⎞
× 8640 × 0.25 ⎟
⎜
2
⎝
⎠
The above table shows that the total cost of 500 units including ordering and carrying
cost is minimum (` 46,64,875) where the order size is 300 units. Hence the most
economical purchase level is 300 units.
(ii) EOQ =
2AO
=
c×i
2 × 500 × 12500
= 69 tonnes.
10500 × 25
Question 14
IPL Limited uses a small casting in one of its finished products. The castings are purchased
from a foundry. IPL Limited purchases 54,000 castings per year at a cost of ` 800 per casting.
The castings are used evenly throughout the year in the production process on a
360-day-per-year basis. The company estimates that it costs `9,000 to place a single
purchase order and about `300 to carry one casting in inventory for a year. The high carrying
costs result from the need to keep the castings in carefully controlled temperature and
humidity conditions, and from the high cost of insurance.
Delivery from the foundry generally takes 6 days, but it can take as much as 10 days. The
days of delivery time and percentage of their occurrence are shown in the following tabulation:
Delivery time (days)
:
6
7
8
9
10
Percentage of occurrence
Required:
:
75
10
5
5
5
(i)
Compute the economic order quantity (EOQ).
(ii)
Assume the company is willing to assume a 15% risk of being out of stock. What would
be the safety stock? The re-order point?
© The Institute of Chartered Accountants of India
Materials
2.15
(iii) Assume the company is willing to assume a 5% risk of being out of stock. What would be
the safety stock? The re-order point?
(iv) Assume 5% stock-out risk. What would be the total cost of ordering and carrying
inventory for one year?
(v) Refer to the original data. Assume that using process re-engineering the company
reduces its cost of placing a purchase order to only `600. In addition company estimates
that when the waste and inefficiency caused by inventories are considered, the true cost
of carrying a unit in stock is ` 720 per year.
(a) Compute the new EOQ.
(b)
How frequently would the company be placing an order, as compared to the old
purchasing policy?
Answer
(i)
Computation of economic order quantity (EOQ)
(A) Annual requirement
= 54,000 castings
(C) Cost per casting
= ` 800
(O) Ordering cost
= ` 9,000 / order
(c × i)Carrying cost per casting p.a
= ` 300
EOQ =
2AO
=
c ×i
2 × 54000 × 9000
=
300
1800 casting
(ii) Safety stock
(Assuming a 15% risk of being out of stock)
Safety stock for one day
=
54,000/360 days = 150 castings
Re-order point
=
Minimum stock level + Average lead time
× Average consumption
=
150 + 6 × 150 = 1,050 castings.
(iii) Safety stocks
(Assuming a 5% risk of being out of stock)
Safety stock for three days
= 150× 3 days
= 450 castings
Re-order point
= 450 casting + 900 castings
=1,350 castings
(iv) Total cost of ordering
= (54,000/1,800) × ` 9,000
=
` 2,70,000
Total cost of carrying
= (450 + ½ × 1,800) ` 300
=
` 4,05,000
© The Institute of Chartered Accountants of India
2.16
Cost Accounting
(v) (a) Computation of new EOQ:
EOQ =
2 × 54,000 × 600
720
= 300 castings
(b) Total number of orders to be placed in a year are 180. Each order is to be placed
after 2 days (1 year = 360 days). Under old purchasing policy each order is placed
after 12 days.
Question 15
Write short notes on any three of the following:
(i)
Re-order quantity
(ii)
Re-order level
(iii) Maximum stock level
(iv) Minimum stock level
Answer
(i)
Re-order quantity: It refers to the quantity of stock for which an order is to be placed at
any one point of time. It should be such that it minimises the combined annual costs ofplacing an order and holding stock. Such an ordering quantity in other words is known as
economic order quantity (EOQ).
EOQ =
2AO
C×i
A
=
Annual raw material usage quantity
O
=
Ordering cost per order
C
=
Cost per unit
i
=
Carrying cost percentage per unit per annum
(ii) Re-order level: It is the level at which fresh order should be placed for the replenishment
of stock.
= Maximum re-order period × Maximum usage
Average time to
⎡ Average
⎤
= Minimum level + ⎢
×
obtain fresh sup plies ⎥⎦
⎣consumption
© The Institute of Chartered Accountants of India
Materials
2.17
(iii) Max stock level: It indicates the maximum figure of stock held at any time.
Minimum ⎤
⎡
Minimum
⎢
= Re – order + Re – order – ⎢
× re – order ⎥⎥
consumptio
n
Level
quantity
⎢⎣
period ⎥⎦
(iv) Minimum stock level: It indicates the lowest figure of stock balance, which must be
maintained in hand at all times, so that there is no stoppage of production due to nonavailability of inventory.
= Re– order –
level
⎡
⎢ Average rate of ×
⎢ consumption
⎣
⎤
Average time of ⎥
stock delivery ⎥⎦
Question 16
Discuss the accounting treatment of spoilage and defectives in Cost Accounting.
Answer
Accounting treatment of spoilage and defectives in Cost Accounting:
Normal spoilage cost (which is inherent in the operation) are included in cost either by
charging the loss due to spoilage to the production order or charging it to production overhead
so that it is spread over all products. Any value realized from the sale of spoilage is credited to
production order or production overhead account, as the case may be.
The cost of abnormal spoilage (i.e. spoilage arising out of causes not inherent in
manufacturing process) is charged to the Costing Profit and Loss Account. When spoiled work
is due to rigid specifications, the cost of spoiled work is absorbed by good production, while
the cost of disposal is charged to production overheads.
The problem of accounting for defective work is the problem of accounting of the costs of
rectification or rework. The possible ways of treatment are as below:
(i)
Defectives that are considered inherent in the process and are identified as normal can
be recovered by using the following methods:
¾ Charged to good products
¾ Charged to general overheads
¾ Charged to department overheads
¾ Charged to identifiable job.
(ii)
If defectives are abnormal and are due to causes beyond the control of organisation, the
rework, cost should be charged to Costing Profit and Loss Account.
© The Institute of Chartered Accountants of India
2.18
Cost Accounting
Question 17
A company manufactures 5000 units of a product per month. The cost of placing an order is `
100. The purchase price of the raw material is ` 10 per kg. The re-order period is 4 to 8
weeks. The consumption of raw materials varies from 100 kg to 450 kg per week, the average
consumption being 275 kg. The carrying cost of inventory is 20% per annum.
You are required to calculate
(i)
Re-order quantity
(iii) Maximum level
(ii)
Re-order level
(iv)
Minimum level
(v) Average stock level
Answer
(i)
Reorder Quantity (ROQ)
(ii) Reorder level (ROL)
=
1,196 kgs. (Refer to working note)
=
Maximum usage × Maximum re-order period
450 kgs × 8 weeks = 3,600 kgs
(iii) Maximum level
(iv) Minimum level
(v) Average stock level
=
Min.
⎛ Min.
⎞
⎟⎟
×
ROL + ROQ – ⎜⎜
⎝ usage re – order period ⎠
=
3,600 kgs + 1,196 kgs – [100 kgs.×4 weeks] = 4,396 kgs.
=
⎛ Normal Normal
⎞
⎟
×
ROL – ⎜⎜
re – order period ⎟⎠
⎝ usage
=
3,600 kgs. – [275 kgs × 6 weeks]
=
1,950 kgs.
=
1
2
=
1
[4,396 kgs. + 1,950 kgs.] = 3,173 kgs.
2
⎛ Maximum Minimum ⎞
⎜⎜
⎟⎟
+
level
⎝ level
⎠
OR
=
[Minimum level +
=
[1,950 kgs +
© The Institute of Chartered Accountants of India
1
ROQ]
2
1
× 1,196 kgs.] = 2,548 kgs.
2
Materials
2.19
Working note
Annual consumption of raw material (S) =
14,300 kgs.
(275 kgs. × 52 weeks)
Cost of placing an order (C0)
=
` 100
Carrying cost per kg. Per annum (iC1) =
Economic order quantity (EOQ)
20
× ` 10 = ` 2
100
=
2SC 0
iC1
=
2 ×14,300 kgs. × ` 100
= 1,196 Kgs.
`2
Question 18
A company manufactures a product from a raw material, which is purchased at `60 per kg.
The company incurs a handling cost of ` 360 plus freight of ` 390 per order. The incremental
carrying cost of inventory of raw material is ` 0.50 per kg. per month. In addition, the cost of
working capital finance on the investment in inventory of raw material is ` 9 per kg. per
annum. The annual production of the product is 1,00,000 units and 2.5 units are obtained from
one kg of raw material.
Required
(i)
Calculate the economic order quantity of raw materials.
(ii)
Advise, how frequently should orders for procurement be placed.
(iii) If the company proposes to rationalize placement of orders on quarterly basis, what
percentage of discount in the price of raw materials should be negotiated?
Answer
A
(Annual requirement of raw material in kgs.) = 1 kg. × 1,00,000 units / 2.5 units = 40,000 kgs.
O
(Handling & freight cost per order) = ` 360 + ` 390 = ` 750
Ci
(Carrying cost per unit per annum + Investment cost per Kg. per annum)
=
(0.5 × 12 months) + ` 9 (investment in inventory per kg. per annum)
=
` 15 per Kg
(i)
E.O.Q.
=
2 × 40,000kgs. × ` 750
= 2,000 Kgs.
` 15
© The Institute of Chartered Accountants of India
2.20
Cost Accounting
(ii) Frequency of orders for procurement:
S (Annual consumption)
= 40,000 kgs.
Quantity per order
= 2,000 kgs.
No. of orders per annum
= 20 (40,000 kgs / 2,000 kgs.)
Frequency of placing orders 0.6 months or 18 days (approx.)
(12 months / 20 orders) or 365 days / 20 orders
(iii) Percentage of discount in the price of raw materials to be negotiated:
= 10,000 kgs. Per order
Quarterly orders
(40,000 kgs / 4 orders)
No. of orders
=4
Total cost
(when order size is 10,000 Kgs)
Order placing cost
`3,000
(4 orders × `750)
Carrying cost
`75,000
(10,000/2×`15)
`78,000
Total Cost
(When order size is equal to EOQ)
No. of orders
20
Order placing cost
(20 orders × ` 750)
` 15,000
Carrying cost
(2,000/2 × ` 15)
` 15,000
` 30,000
Increase in cost to be compensated by discount:
` 48,000
(` 78,000 – ` 30,000)
Reduction per kg. In the purchase price of raw material:
` 1.20 per kg
(` 48,000/40,000 Kgs.)
Percentage of discount in the price of raw material to be negotiated : 2% discount
⎛ ` 1.20 ⎞
⎜ 60 ⎟ × 100
⎝
⎠
© The Institute of Chartered Accountants of India
Materials
2.21
Question 19
The quarterly production of a company's product which has a steady market is 20,000 units.
Each unit of a product requires 0.5 Kg. of raw material. The cost of placing one order for raw
material is ` 100 and the inventory carrying cost is ` 2 per annum. The lead time for
procurement of raw material is 36 days and a safety stock of 1,000 kg. of raw materials is
maintained by the company. The company has been able to negotiate the following discount
structure with the raw material supplier.
Order quantity
Discount
Kgs.
(`)
Upto 6,000
NIL
6,000 – 8,000
400
8,000 – 16,000
2,000
16,000 – 30,000
3,200
30,000 – 45,000
You are required to
4,000
(i)
Calculate the re-order point taking 30 days in a month.
(ii)
Prepare a statement showing the total cost of procurement and storage of raw material
after considering the discount of the company elects to place one, two, four or six orders
in the year.
(iii) State the number of orders which the company should place to minimize the costs after
taking EOQ also into consideration
Answer
Working notes
1.
Annual production (units)
80,000
(20,000 units per quarter × 4 quarters)
2.
Raw material required for 80,000 units in kgs.
40,000
(80,000 units × 0.5 kgs.)
2 × 40,000 kgs. × ` 100
= 2,000 kgs.
`2
3.
EOQ =
4.
Total cost of procurement and storage when
the order size is equal to EOQ or 2,000 kgs.
No. of orders
© The Institute of Chartered Accountants of India
20
2.22
Cost Accounting
(40,000 kgs. / 2,000 kgs.)
Ordering cost (`)
2,000
(20 orders × ` 100)
Carrying cost (`)
2,000
(½ × 2,000 kgs. × ` 2)
_____
Total cost
4,000
(i)
Reorder point
=
Lead time consumption + Safety stock
=
4,000 kgs. + 1,000 kgs. = 5,000 kgs.
(40,000 kgs. / 360 days) × 36 days.
(ii)
Statement showing the total cost of
procurement and storage of raw materials
(after considering the discount)
Order size
No. of
orders
Kgs.
(1)
(2)
Total cost of
procurement
Average
stock
Total cost
of storage
of raw
materials
(`)
Kgs.
(`)
(`)
(`)
(3)=(2)×`100
(4)=½×(1
)
(5)=(4)×`2
(6)
(7)=[(3)+(5)–
(6)
Discount Total cost
40,000
1
100
20,000
40,000
4,000
36,100
20,000
2
200
10,000
20,000
3,200
17,000
10,000
4
400
5,000
10,000
2,000
8,400
6666.66
6
600
3,333
6,666
400
6,866
(iii) Number of orders which the company should place to minimize the costs after
taking EOQ also into consideration is 20 orders each of size 2,000 kgs. The total
cost of procurement and storage in this case comes to ` 4,000, which is minimum.
(Refer to working notes 3 and 4)
Question 20
Write short note on perpetual inventory control.
Answer
Perpetual Inventory: It represents a system of records maintained by the stores in
department. It in fact comprises of:
© The Institute of Chartered Accountants of India
Materials
(i)
Bin Cards, and
(ii)
Stores Ledger
2.23
Bin Card maintains a quantitative record of receipts, issues and closing balances of each item
of stores. Separate bin cards are maintained for each item. Each card is filled up with the
physical movement of goods i.e. on its receipt and issue.
Like bin cards, the Stores Ledger is maintained to record all receipt and issue transactions in
respect of materials. It is filled up with the help of goods received note and material
requisitions.
A perpetual inventory is usually checked by a programme of continuous stock taking.
Continuous stock taking means the physical checking of those records (which are maintained
under perpetual inventory) with actual stock. Perpetual inventory is essentially necessary for
material control. It incidentally helps continuous stock taking.
The success of perpetual inventory depends upon the following: (a) The Stores Ledger-(showing quantities and amount of each item)
(b) Stock Control Cards (or Bin Cards)
(c) Reconciling the quantity balances shown by (a) & (b) above'
(d) Checking the physical balances of a number of items every day systematically and by
rotation
(e) Explaining promptly the causes of discrepancies, if any, between physical balances and
book figures
(f)
Making corrective entries were called for after step (e) and
(g) Removing the causes of the discrepancies referred to step (e).
The main advantages of perpetual inventory are as follows :
(1) Physical stocks can be counted and book balances adjusted as and when desired
without waiting for the entire stock-taking to be done.
(2) Quick compilation of Profit and Loss Accounts (for interim period) due to prompt
availability of stock figures.
(3) Discrepancies are easily located and thus corrective action can be promptly taken to
avoid their recurrence.
(4) A systematic review of the perpetual inventory reveals the existence of surplus, dormant,
obsolete and slow-moving materials, so that remedial measures may be taken in time.
(5) Fixation of the various levels and check of actual balances in hand with these levels
assist the Storekeeper in maintaining stocks within limits and in initiating purchase
requisitions for correct quantity at the proper time.
© The Institute of Chartered Accountants of India
2.24
Cost Accounting
Question 21
PQR Ltd., manufactures a special product, which requires ‘ZED’. The following particulars
were collected for the year 2005-06:
(i)
Monthly demand of Zed
7,500 units
(ii)
Cost of placing an order
` 500
(iii)
Re-order period
5 to 8 weeks
(iv)
Cost per unit
` 60
(v)
Carrying cost % p.a.
10%
(vi)
Normal usage
500 units per week
(vii)
Minimum usage
250 units per week
(viii) Maximum usage
Required:
750 units per week
(i)
Re-order quantity.
(ii)
Re-order level.
(iii) Minimum stock level.
(iv) Maximum stock level.
(v) Average stock level.
Answer
(i)
2AO
Re - order quantity =
=
C×i
2 × 7,500 × 12 × 500
60 × 10
= 3,873 units
(ii) Re-order level
= Maximum re-order period × Maximum usage
= 8 weeks × 750 units per week = 6,000 units
(iii) Minimum stock level
= Re-order level – {Normal usage × Average reorder period}
= 6,000 – (500 × 6.5) = 2,750 units
(iv) Maximum stock level
= Re-order level + Re-order quantity – (Minimum usage × Minimum re-order period)
© The Institute of Chartered Accountants of India
Materials
2.25
= 6,000 + 3,873 – (5 × 250) = 8,623 units
(v) Average stock level
= ½ (Minimum stock level + Maximum stock level)
= ½ (2,750 + 8,623) = 5,687 units
Question 22
Raw materials ‘AXE’ costing ` 150 per kg. and ‘BXE’ costing ` 90 per kg. are mixed in equal
proportions for making product ‘A’. The loss of material in processing works out to 25% of the
product. The production expenses are allocated at 40% of direct material cost. The end
product is priced with a margin of 20% over the total cost.
Material ‘BXE’ is not easily available and substitute raw material ‘CXE’ has been found for
‘BXE’ costing ` 75 per kg. It is required to keep the proportion of this substitute material in the
mixture as low as possible and at the same time maintain the selling price of the end product
at existing level and ensure the same quantum of profit as at present.
You are required to compute the ratio of the mix of the raw materials ‘AXE’ and ‘CXE.
Answer
Working Notes:
(i)
Computation of material mix ratio:
Let 1 kg. of product A requires 1.25 kg. of input of materials A X E and B X E
Raw materials are mixed in equal proportions.
Then raw material A X E =
1.25
= .625 kg.
2
Then raw material B X E =
1.25
= .625 kg.
2
(ii) Computation of selling price / kg. of product A
(`)
Raw material A X E .625 kg. × 150 = ` 93.75
Raw material B X E .625 kg. × 90 = ` 56.25
Production expenses (40% of material cost)
Total cost
Add: profit 20% of total cost
Selling price
Computation of proportions of materials A X E and C X E in ‘A’
Let material C X E required in product A be m kg.
© The Institute of Chartered Accountants of India
150.00
60.00
210.00
42.00
252.00
2.26
Cost Accounting
Then for producing 1 kg of product ‘A’, material A X E requirement = (1.25 − m) kg.
To maintain same level of profit and selling price as per Working note (ii), it is required
that the total cost of material in 1 kg. of product A should not exceed
` 150,
i.e., m kg. × ` 75 + (1.25 −m) kg. × 150 = ` 150
or 75 m + 187.5 – 150 m = 150
or 75 m = 37.5
or m = 0.5 kg.
Raw material A X E requirement in product A = 1.25 – .5 = .75 kg.
So, proportion of material A X E and C X E
= .75 : .50
i.e. 3 : 2.
Question 23
Explain Bin Cards and Stock Control Cards.
Answer
Bin Cards and Stores control cards:
Bin Cards are quantitative records of the stores receipt, issue and balance. It is
kept for each and every item of stores by the store keeper. Here, the balance is taken out after
each receipt or issue transaction
Stock control cards are also similar to Bin Cards. Stock control cards contain
further information as regards stock on order. These cards are kept in cabinets or trays or
loose binders.
Question 24
A Company manufactures a special product which requires a component ‘Alpha’.
following particulars are collected for the year 2008:
(i)
Annual demand of Alpha
:
8,000 units
(ii)
Cost of placing an order
:
(iii)
Cost per unit of Alpha
:
` 200 per order
` 400
(iv)
Carrying cost % p.a.
:
20%
The
The company has been offered a quantity discount of 4% on the purchase of ‘Alpha’, provided
the order size is 4,000 components at a time.
© The Institute of Chartered Accountants of India
Materials
2.27
Required:
(i)
Compute the economic order quantity.
(ii)
Advise whether the quantity discount offer can be accepted.
Answer
(a)
EOQ =
=
2 AO
C×i
2 × 8,000 × 200
400 × 20%
= 200 units.
Calculation of total inventory cost p.a. at EOQ.
(`)
Purchase cost = 8,000 × 400
8,000
⎛A
⎞
Ordering cost ⎜ × O =
× 200 ⎟ =
200
⎝Q
⎠
200
⎛Q
⎞
Carrying cost ⎜ × c × i =
× 400 × 20% ⎟ =
2
2
⎝
⎠
32,00,000
8,000
8,000
32,16,000
Calculation of total inventory cost p.a. with quantity discount
(`)
Purchase cost = 8,000 × (400 − 4%)
8,000
⎛A
⎞
× 200 ⎟ =
Ordering cost ⎜ × O =
4,000
⎝Q
⎠
4,000
⎛Q
⎞
× 384 × 20% ⎟ =
Carrying cost = ⎜ × c × i =
2
2
⎝
⎠
30,72,000
400
1,53,600
32,26,000
Quantity discount offered should not be accepted as it results in increase in total cost of
inventory management by ` 10,000.
Question 25
(a) The following are the details of receipts and issues of a material of stores in a
manufacturing company for the period of three months ending 30th June, 2008:
© The Institute of Chartered Accountants of India
2.28
Cost Accounting
Receipts:
Date
Quantity (kgs)
Rate per kg.
(` )
April 10
1,600
5
April 20
2,400
4.90
May 5
1,000
5.10
May 17
1,100
5.20
May 25
800
5.25
June 11
900
5.40
June 24
1,400
5.50
There was 1,500 kgs. in stock at April 1, 2008 which was valued at ` 4.80 per kg.
Issues:
Date
Quantity (kgs)
April 4
1,100
April 24
1,600
May 10
1,500
May 26
1,700
June 15
1,500
June 21
1,200
Issues are to be priced on the basis of weighted average method. The stock verifier of
the company reported a shortage of 80 kgs. on 31st May, 2008 and 60 kgs. on 30th
June, 2008. The shortage is treated as inflating the price of remaining material on
account of shortage.
You are required to prepare a Stores Ledger Account.
Answer
Stores Ledger Account
for the three months ending 30th June, 2008
(Weighted Average Method)
(a)
Receipts
Date
GRN
No.
MRR
No.
Qty.
(Kgs.)
Rates
(`)
Issues
Amounts
Requisition. No.
2008
April 1
© The Institute of Chartered Accountants of India
Qty.
(Kgs.)
Rates Amount
(`)
(`)
Balance
Qty.
(Kgs.)
1,500
Amount
(`)
7,200
Rate for further
Issue (`)
4.80
Materials
1,100
April 4
April 10
1,600
5.00
8,000
400
2,000
1,920
9,920
April 20
2,400
4.90
11,760
4,400
21,680
21,680
= 4.93
4,400
2,800
13,792
13,792
= 4.93
2,800
3,800
18,892
18,892
= 4.97
3,800
2,300
11,437
11,437
= 4.97
2,300
April 24
May 5
1,600
1,000
5.10
4.80
4.93
5,280
2.29
7,888
5,100
May 10
1,500
4.97
7,455
4.80
9,920
= 4.96
2,000
May 17
1,100
5.20
5,720
3,400
17,157
17,157
= 5.05
3,400
May 25
800
5.25
4,200
4,200
21,357
21,357 = 5.09
4,200
2,500
12,704
12,704
= 5.09
2,500
2,420
12,704
12,704
= 5.25
2,420
3,320
17,564
17,564
= 5.29
3,320
May 26
1,700
May 31
June 11
Shortage
900
5.40
5.09
8,653
80
4,860
June 15
1,500
5.29
7,935
1,820
9,629
9,629
= 5.29
1,820
June 21
1,200
5.29
6,348
620
3,281
3,281
= 5.29
620
2,020
10,981
10,981
= 5.40
2,020
1,960
10,981
10,981
= 5.60
1,960
June 24
1,400
5.50
June 30
7,700
Shortage
60
Question 26
Explain why the Last in First out (LIFO) has an edge over First in First out (FIFO) or any other
method of pricing material issues.
Answer
LIFO has following advantages:
(a) The cost of the material issued will be reflecting the current market price.
(b) The use of the method during the period of rising prices does not reflect undue high profit
in the income statement.
(c) In the case of falling price, profit tend to rise due to lower material cost, yet the finished
goods appear to be more competitive and are at market price.
(d) During the period of inflation, LIFO will tend to show the correct profit.
© The Institute of Chartered Accountants of India
2.30
Cost Accounting
Question 27
ZED Company supplies plastic crockery to fast food restaurants in metropolitan city. One of
its products is a special bowl, disposable after initial use, for serving soups to its customers.
Bowls are sold in pack 10 pieces at a price of ` 50 per pack.
The demand for plastic bowl has been forecasted at a fairly steady rate of 40,000 packs every
year. The company purchases the bowl direct from manufacturer at ` 40 per pack within a
three days lead time. The ordering and related cost is ` 8 per order. The storage cost is 10%
per cent per annum of average inventory investment.
Required:
(i)
Calculate Economic Order Quantity.
(ii)
Calculate number of orders needed every year.
(iii) Calculate the total cost of ordering and storage bowls for the year.
(iv) Determine when should the next order to be placed. (Assuming that the company does
maintain a safety stock and that the present inventory level is 333 packs with a year of
360 working days.
Answer
(i)
Economic Order Quantity
EOQ =
=
2×A×O
Ci
2 × 40,000 × 8
4
= 1,60,000 = 400 packs.
(ii) Number of orders per year
Annual requirements
Economic order quantity
40,000
= 100 order per year
400
(iii) Ordering and storage costs
(`)
Ordering costs :– 100 orders × ` 8.00
800
Storage cost :– (400/2) × (10% of 40)
800
Total cost of ordering & storage
© The Institute of Chartered Accountants of India
1,600
Materials
2.31
(iv) Timing of next order
(a) Day’s requirement served by each order.
Number of days requirements =
No. of working days
No. of order in a year
=
360
= 3.6 days supply
100
This implies that each order of 400 packs supplies for requirements of 3.6 days only.
(b) Days requirement covered by inventory
=
∴
Units in inventory
× (Day requirement served by an order)
Economic order quantity
333
× 3.6 days = 3 days requirement
400
(c) Time interval for placing next order
Inventory left for day’s requirement – Lead time of delivery
3 day’s requirements – 3 days lead time = 0
This means that next order for the replenishment of supplies has to be placed
immediately.
Question 28
The annual carrying cost of material ‘X’ is ` 3.6 per unit and its total carrying cost is ` 9,000
per annum. What would be the Economic order quantity for material ‘X’, if there is no safety
stock of material X ?
Answer
Calculation of Economic Order Quantity
Average Inventory =
Total Carrying Cost
Carrying Cost per unit
=
` 9,000
= 2,500 Units
` 3.60
Economic Order Quantity = Average Inventory × 2
= 2,500 × 2 = 5,000 units.
Alternative Solution:
Total Carrying Cost =
Carrying cost per unit × E.O.Q
2
© The Institute of Chartered Accountants of India
2.32
Cost Accounting
or 9,000 =
3.6 × E.O.Q
2
or E.O.Q. =
9,000 × 2
= 5,000 unit
3.6
Question 29
Differentiate between “scrap” and ”defectives” and how they are treated in cost accounting.
Answer
Scrap: Scrap is incidental residence from certain type of manufacture, usually of small amount
and low value, recoverable without further processing.
The cost of scrap is borne by good units and income scrap is treated as other income.
Defectives: Defectives are portion of production which can be rectified by incurring additional
cost. Normal defectives can be avoided by quality control. Normal defectives are charged to
good products.
Abnormal defectives are charged to Costing Profit and Loss Account
Question 30
The following information relating to a type of Raw material is available:
Annual demand
2000 units
Unit price
Ordering cost per order
`20.00
`20.00
Storage cost
2% p.a.
Interest rate
8% p.a.
Lead time
Half-month
Calculate economic order quantity and total annual inventory cost of the raw material.
Answer
EOQ
=
=
2 × Annual Consumption × Buying Cost per Order
Storage Cost per unit
2 × 2,000 × 20
=
⎛ 2+8 ⎞
` 20 × ⎜
⎟
⎝ 100 ⎠
80,000
= 200 Units
2
Total Annual Inventory Cost
Cost of 2,000 Units @ `20 (2,000 × 20)
© The Institute of Chartered Accountants of India
=
`40,000
Materials
No. of Order
2.33
2000
= 10
200
Ordering Cost 10 × ` 20
Carrying cost of Average Inventory
200
10
× 20 ×
2
100
=
`200
=
`200
=
`40,400
Question 31
Re-order quantity of material ‘X’ is 5,000 kg.; Maximum level 8,000 kg.; Minimum usage 50 kg.
per hour; minimum re-order period 4 days; daily working hours in the factory is 8 hours. You
are required to calculate the re-order level of material ‘X’.
Answer
Maximum Level = Re-order level + Re-order Quantity-(Minimum usage per day × Minimum
Re-order Period)
Re-order Level = Maximum Level – [Re-order quantity – (Minimum usage per day × Minimum
Re-order Period)
= 8000 kg. – [5000 kg. – (400 kg* × 4)] = 8000 kg. – 3400 kg. = 4600 kg.
Hence, Re-order level is 4600 kg.
*Minimum usage per day = 50 kg. × 8 = 400 kg.
Question 32
Prepare a Store Ledger Account from the following transactions of XY Company Ltd.
April, 2011
1
Opening balance 200 units @ ` 10 per unit.
5
Receipt 250 units costing ` 2,000
8
Receipt 150 units costing ` 1,275
10 Issue 100 units
15 Receipt 50 units costing ` 500
20 Shortage 10 units
21 Receipt 60 units costing ` 540
22 Issue 400 units
The issues upto 10-4-11 will be priced at LIFO and from 11-4-11 issues will be priced at FIFO.
Shortage will be charged as overhead.
© The Institute of Chartered Accountants of India
2.34
Cost Accounting
Answer
(a)
Store Ledger Account
Name :Code No. :Description:Date
April 1
” 5
”
8
Max. Stock Level Min. Stock Level Re-order level –
Re-order quantityReceipts
Issues
Qty. Rate Amount
Qty. Rate
Units
Units
(`)
(`)
250
8
2,000
150
8.50
1,275
(`)
” 10
” 15
100
50
10
10
(shortage)
60
9
Amount
10
8.50
100
540
” 22
© The Institute of Chartered Accountants of India
190
210
10
8
Qty.
(`)
500
” 20
” 21
8.50
Bin No.Location Code-
3,580
Balance
Rate Amount
(`)
(`)
200
200
250
200
250
150
200
250
50
200
250
50
50
190
10
10
8
10
8
8.50
10
8
8.50
10
8
8.50
10
10
2,000
250
50
50
190
8
8.50
10
10
4,825
250
8
50
50
60
40
50
50
60
8.50
10
9
8
8.50
10
9
4,000
5,275
4,425
4,925
5,365
1,785
(Closing
Stock)
Materials
2.35
Question 33
Distinguish between bill of material and material requisition note.
Answer
Bills of material
It is document by the drawing office
Material Requisition Note
1.
1. It is prepared by the foreman of the
consuming department.
2. It is a complete schedule of 2. It is a document authorizing Storecomponent parts and raw materials Keeper to issue Material to the
required for a particular job or work consuming department.
order.
3. It often serves the purpose of a 3. It cannot replace a bill of material.
Store Requisition as it shown the
complete schedule of materials required
for a particular job i.e. it can replace
stores requisition.
4. It can be used for the purpose of 4. It is useful in arriving historical cost
quotation
only.
5. It helps in keeping a quantitative 5. It shows the material actually drawn
control on materials draw through stores from stores.
Requisition.
Question 34
KL Limited produces product 'M' which has a quarterly demand of 8,000 units. The product
requires 3 kgs quantity of material 'X' for every finished unit of product. The other information
are follows:
Cost of material 'X'
:
Cost of placing an order
:
` 20 per kg.
` 1000 per order
Carrying Cost
:
15% per annum of average inventory
You are required:
(i)
Calculate the Economic Order Quantity for material 'X'.
(ii)
Should the' company accept an offer of 2 percent discount by the supplier, if he wants to
supply the annual requirement of material 'X' in 4 equal quarterly installments?
Answer
Annual demand of material ‘X’
= 8000 units (per quarter) x 4 (No. of Quarter in a year) x 3 kgs (for every finished product)
= 96,000 kgs.
© The Institute of Chartered Accountants of India
2.36
(i)
Cost Accounting
Calculation of Economic Order Quantity (EOQ) for material ‘X’
EOQ =
=
2 x Annual demand x ordering cost
Carrying cost per unit per annum
2 × 96,000 kg × ` 1000
` 20 × 15%
= 8,000 kg.
(ii) Evaluation of Cost under different options of ‘order quantity’.
Particulars
When EOQ is ordered
When discount of 2% is
accepted and supply is in 4
equal installments
Order size
8000 kgs
96,000Kgs
= 24,000 kgs
4
No. of order
96000 kgs
8000 kgs
Purchase Cost per kg.
96000 kgs
= 12
24,000 kgs
=4
` 20
(20-2% ` 20) = ` 19.60
Total Purchase Cost (A)
(96,000 kgs x ` 20)
=`19,20,000
(96,000 kgs x 19.6)=
`18,81,600
Ordering Cost (B)
12 orders x ` 1000
=`12,000
4 orders x ` 1000 = ` 4,000
Carrying Cost (C)
8000 kgs
2
× 15% x 20 =
` 12,000
24000 kgs
2
x 15% 19.6 =
` 35,280
Total Cost (A+B+C)
` 19,44,000
`19,20,880
Advice – The total Cost is lower if Company accept an offer of 2 percent discount by the
supplier, when supply of the annual requirement of material ‘X’ is made in 4 equal
installments.
Question 35
Assume that the following quantity discount schedule for a particular bearing is available to a
retail store:
Order size (unit)
0 - 49
50 - 99
100 - 199
200 and above
© The Institute of Chartered Accountants of India
Discount
0%
5%
10%
12%
Materials
2.37
The cost of a single bearing with no discount is ` 30. The annual demand is 250 units.
Ordering cost is ` 20 per order and annual inventory carrying cost is ` 4 per unit. Determine
the optimal order quantity and the associated minimal total cost of inventory and purchasing
costs, if shortages are not allowed.
Answer
Working Notes
1.
EOQ without discount
EOQ =
=
2.
2A0
C
=
2 × 250 × 20
4
2,500 =50 units
Prices with discount for different order size
5% Discount = 30 – 5% = ` 28.50
10% Discount = 30 – 10% = ` 27.00
12% Discount = 30 – 12%= ` 26.40
Statement of Computing Total cost at various order sizes
Orders
No. of Orders
size (units)
in a year
Ordering
Cost (`)
Carrying cost of
Purchase
average
cost (`)
inventory (`)
1
2
3
4
5
250
50
250 × 28.50 =
=5
× 4 = 100
50
5×20 = 100
7,125
50
2
250
100 ×
250 × 27 =
= 2.5
4= 200
2.5 × 20 = 50
100
6,750
100
2
250
125
250 × 27 =
=2
× 4 = 250
2×20 = 40
125
6,750
125
2
250
200
1.25 × 20 =
250 × 26.40 =
= 1.25
× 4 = 400
200
25
6,600
200
2
250
250
250 × 26.40 =
=1
× 4= 500
1 × 20 = 20
250
6,600
250
2
Optimal order quantity = 100 units
Total cost
(`)
(3+4+5)= 6
7,325
7,000
7,040
7,025
7,120
Minimum total cost of inventory and purchasing cost = ` 7,000.
Note: Theoretically it may be 2.5 orders, (250÷100), however practically 3 orders are required.
Therefore ordering cost would be ` 60 (3 × 20) and total cost ` 7,010 (60 + 200 + 6750).
© The Institute of Chartered Accountants of India
2.38
Cost Accounting
Question 36
State whether the following statements are correct. Give reasons:
(i)
Safety stock increases as demand increases.
(ii)
In ABC analysis high cost items are most likely to fall in category A, and least cost items
are likely to fall in category C.
(iii) To protect against stock outs, a large batch size is a must.
(iv) E.O.Q. is based on a balancing between inventory carrying cost and shortage costs.
(v) Lead time is the time interval elapsing between the placement of a replenishment order
and the receipt of last installment of goods against the order.
Answer
Sl No.
(i)
True/Not True
Not true
(ii)
Not true
(iii)
True
(iv)
Not true
(v)
Not true
Reason
Safety stock is held for meeting the unpredictable
fluctuation in the demand and supply. It varies with the
fluctuations in demand and not with level of demand.
The categorization of A, B and C is done on the basis of
their annual usage value (Consumption value) and not on
their cost X, Y and Z. Analysis is done on the basis of
value of inventory stored.
If the batch size is large, number of orders in a year will
be lower. Hence stock moves to lowest point (re-order
level) fewer times a year. Hence danger of stock out will
be less. Thus to protect against stock out, a large batch
size is a must.
E.O.Q. is based on a balancing between ordering cost
and carrying cost of inventory. It does not take into
account the shortage cost.
Lead time is the time interval elapsing between the
placement of a replenishment order and the receipt of
first instalment of goods against the order.
Question 37
The following data are available in respect of material X for the year ended 31st March, 2013:
Opening stock
` 90000
Purchases during the year
270000
Closing stock
110000
Calculate: (i) Inventory turnover ratio and (ii) the number of days for which the average
inventory is held.
© The Institute of Chartered Accountants of India
Materials
2.39
Answer
Working Notes
(a) Opening stock
` 90000
Add: Purchases
270000
360000
Less: Closing stock
110000
Material consumed during the year
250000
(b) Average stock
=
OpeningStock + Clo singStock
2
=
90,000 + 1,10,000
= 1,00,000
2
(i) Inventory turnover Ratio =
MaterialConsumed
AverageStock
=
2,50,000
= 2.5 times
1,00,000
(ii) 2,50,000 consumption
365 days
1,00,000 average inventory
1,00,000
2,50,000
Or
x 365 =
?
146 days for which the average inventory held.
No.daysina year
Inventory Turnover ratio
=
365
= 146days
2.5
Question 38
The following transactions in respect of material Y occurred during the six months ended 30th
June, 2012:
Month
Purchase (units)
Price per unit(`)
Issued units(`)
January
200
25
Nill
February
300
24
250
March
425
26
300
April
475
23
550
May
500
25
800
June
600
20
400
© The Institute of Chartered Accountants of India
2.40
Cost Accounting
Required
The chief accountant argues that the value of closing stock remains the same no matter which
method of pricing of material issues is used. Do you agree? Why or why not? Detailed stores
ledgers are not required.
Answer
Assumption: No opening stock on 1st January 2012
Materials Cost and Control
Month
January 2012
February
March
April 1
May
June 2012
Opening
balance
Nil
200
250
375
300
Nil
Purchases
Issues
200
300
425
475
500
600
250
300
550
800
400
Closing
balance (units)
200
250
375
300
Nil
200
At the end of May 2012, there was no closing stock, i.e. no opening stock on 1.6.2012. But
there was closing of 200 units at the end of June 2012.
Value of closing stock at the end of June 2012.
FIFO 200Units at ` 20
=
` 4000
LIFO 200 Units at ` 20
=
` 4000
Weighted average –do--
=
` 4000
Hence the argument of Chief Accountant is correct. He is correct only in the above case. If
there was closing stock at the end of May 2012, the argument of the Chief Accountant will not
be correct.
Question 39
After the annual stock taking you come to know of some significant discrepancies between
book stock and physical stock. You gather the following information:Item
A
B
C
Stock card Units
600
380
750
Stores Ledger Units
600
380
780
Physical Check Units
560
385
720
Cost/unit (`)
60
40
10
(a) What action should be taken to record the information shown.
(b) Suggest reasons for the shortage and discrepancies disclosed above and recommended
a possible course of action by management to prevent future losses.
© The Institute of Chartered Accountants of India
Materials
2.41
Answer
(a) Item A: The shortage of 40 units may be entered in the Stock Card and Stores
Ledger. That means, stock card should reflect the physical quantity only. The
value is ` 2400 (i.e. 40 units at ` 60 per unit).
Accounting treatment
1.
If the shortage is normal:Production Overhead control A/c
Dr. 2400
To Stores Ledger control A/c
2.
2400
If the shortage is abnormal:Costing P&L A/c
Dr. 2400
To Stores Ledger control A/c
3.
2400
If the shortage is due to non-recording or short-recording of direct material
issued to production:
WIP Control A/c
Dr. 2400
To Stores Ledger control A/c
4.
2400
If the shortage is due to non-recording or short-recording of indirect material
issued:Production Overhead control A/c
Dr. 2400
To Stores Ledger control A/c
5.
2400
Clerical errors, if any, should be rectified.
Item B: Excess physical units: 5 value 5 × 40 = ` 200.
Accounting treatment depending on the reason:
1.
If the excess is due to normal causes:
Stores Ledger control A/c
Dr.
200
To Production Overhead control A/c
2.
200
If the excess is due to abnormal causes:
Stores Ledger control A/c
Dr.
200
To Costing P&L A/c
3.
200
If the excess is due to wrong recording of direct material:
Stores Ledger control A/c
To WIP Control A/c
© The Institute of Chartered Accountants of India
Dr.
200
200
2.42
Cost Accounting
4.
If the excess is due to wrong recording of indirect material:
Stores Ledger control A/c
Dr.
200
To Production Overhead control A/c
200
Item C:
Units
Physical stock
720
Stock Card
750
Shortage
30
Value 30 units at ` 10 = ` 300.
Accounting treatment is the same as given in case of Item A. Value is ` 300.
Stock Card
750
Stores Ledger
780
Difference
30 units
Reasons for difference of 30 units between stock card and stores Ledger:
1.
One issue voucher of 30 units might not have been posted in Stores Ledger
2.
There may be clerical errors in balancing, posting etc. After ascertaining,
these may be rectified.
3.
One receipt of 30 units might not have been posted in Stock Card. After
posting of this stock card balance will be 780 units. Then the shortage will be
60 units as compared to physical quantity of 720 units.
(b) Reasons for shortage and discrepancies:
1.
Wastage of material due to spoilage, breakages, evaporation etc. it may be
normal or abnormal.
2.
Theft or pilferage.
3.
Issued but not entered in stock card.
4.
Over issues.
5.
Entering the issue in the wrong stock card.
6.
Clerical errors in balancing or posting etc.
7.
Incorrect entries in stock card.
8.
Goods received and deposited in the wrong bins.
9.
Small defective units – nails, screws etc.
10. Purchase in kgs. but issues to production in numbers i.e. bolts, nuts etc.
Recommended course of action to prevent future losses
© The Institute of Chartered Accountants of India
Materials
2.43
1.
The entries should be correctly entered in stock cards.
2.
Internal check system should be introduced by double checking on the entries.
3.
Entry in the stores should be restricted to authorized persons only.
4.
To avoid pilferage, the store room should be well guarded and protected. (Just like
cash room).
5.
Proper accounting should be done for all stock movements.
6.
FIFO system should be followed while issuing materials (pricing of issue of
materials may be a different method). This will avoid losses due to deterioration or
obsolescence.
7.
All issues of stock should be made on the basis of stores requisition duly signed
by authorised person.
8.
To minimise losses due to breakage in case of heavy and bulky materials,
materials handling equipment like forklift trucks and cranes should be provided.
9.
Wrong issues should be avoided by accurate measuring and weighing equipment
should be inspected / checked periodically.
10. Proper storage conditions should be provided, particularly in the case of
perishable items and items of lesser shelf life.
11. No movement of materials from one place to another place without proper
authorisation and documentation.
EXERCISE
1
List five types of inefficiency in the use of materials that may be discovered as the result of investigating
material quantity variances. What measures may be taken in each such situation to prevent their
recurrence?
Answer
2.
Many businesses have an unnecessarily large amount of capital locked up in the raw materials and work-inprogress. Indicate methods of correcting this position.
Answer
3
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Discuss briefly how the following items are to be treated in costs:(i)
Carriage inwards raw materials
(ii)
Storage losses
(iii)
Cash discount received
(iv)
Insurance costs on stocks of raw materials.
Answer
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
© The Institute of Chartered Accountants of India
2.44
4
Cost Accounting
Distinguish between spoilage and defectives in a manufacturing company. Discuss their treatment in cost
accounts and suggest a procedure for their control.
Answer
5.
What are the conditions that favour the adoption of last-in first-out system of materials pricing? Explain its
working and indicate its advantages and limitations.
Answer
6
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Distinguish between
(a)
Perpetual Inventory System and continuous stock taking.
(b)
Bill of materials and material requisition note
Answer
10
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
What is ABC analysis? Discuss its role in a sound system of material control.
Answer
9
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Explain the distinction between waste and scrap in the manufacturing process. Discuss their treatment in
cost accounts and suggest a procedure for control.
Answer
8
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Define (i) Replacement Price and (ii) Standard Price. Discuss the objectives of these methods of pricing of
materials and state the circumstances in which they are used.
Answer
7.
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Distinguish amongst:
Waste
Spoilage
Salvage
Rectification
Scrap.
How are they treated in Cost Accounts.
Answer
11
Draw a proforma of "Bill of Materials". List down the Advantages of using the same.
Answer
12
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
What is a purchase requisition? Give a specimen form of a purchase requisition.
Answer
17
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Draw specimen draft of a 'Purchase Order'.
Answer
16
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
"To be able to calculate a basic EOQ certain assumptions are necessary. "List down these assumptions.
Answer
15
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Distinguish between perpetual inventory and continuous stock trading.
Answer
14
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Write notes on Bill of Material
Answer
13
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
What do you understand by ABC analysis of inventory control ? A factory uses 4,000 varieties of inventory.
In terms of inventory holding and inventory usage, the following information is compiled:
© The Institute of Chartered Accountants of India
Materials
No. of varieties of
inventory
%
2.45
% value of inventory holding (average)
% of inventory usage
(in end-product)
3,875
96.875
20
5
110
2.750
30
10
15
0.375
50
85
4,000
100.000
100
100
Classify the items of inventory as per ABC analysis with reasons.
Answer
18
Refer to ‘Chapter No.2 i.e. Material’ of Study Material.
The following transactions in respect of material Y occurred during the six months ended 30th June, 1988
Month
Purchase (Units)
Price per Unit
`
January
February
March
April
May
June
200
300
425
475
500
600
25
24
26
23
25
20
Issued
units
Nil
250
300
550
800
400
(a)
The chief accountant argues that the values of closing stock remains the same no matter which
method of pricing of material issues is used. Do you agree? Why or why not? Detailed stores ledgers
are not required.
(b)
When and why would you recommend the LIFO method of pricing material issues?
Answer (a) Correct (b) At the time of inflation
19
The following information is provided by SUNRISE INDUSTRIES for the fortnight of April, 1988:–
Material Exe :
Stock on 1.4.1988 100 units at ` 5 per unit.
Purchases
5-4-88
300 units at ` 6
8-4-88
500 units at ` 7
12-4-88
600 units at ` 8
Issues
6-4-88
250 units
10-4-88
400 units
14-4-88
500 units
Required
(A)
Calculate using FIFO and LIFO methods of pricing issues:
(a)
the value of materials consumed during the period
(b)
the value of stock of materials on 15-4-88.
© The Institute of Chartered Accountants of India
2.46
Cost Accounting
(B)
Explain why the figures in (a) and (b) in part A of this question are different under the two methods of
pricing of material issues used. You NEED NOT draw up the Stores Ledgers.
Answer Total value of material Exe consumed during the period under FIFO method comes to (` 1,400 + `
2,650 – ` 3,750) ` 7,800 and balance on 15.04.88 is of ` 2,800.
Total value of material Exe issued under LIFO method comes to (` 1,500 + ` 2,800 + ` 4,000) ` 8,300
20
About 50 items are required every day for a machine. A fixed cost of ` 50 per order is incurred for placing
an order. The inventory carrying cost per item amounts to ` 0.02 per day. The lead period is 32 days
compute.
(i)
Economic Order Quantity
(ii)
Re-order level
Answer (i) Economic Order Quantity 500 items
(ii)
21
Re-order level 1,600 items
The following data are available in respect of material X for the year ended 31st March 1997.
`
Opening stock
Purchases during the year
Closing stock
90,000
2,70,000
1,10,000
Calculate –
(i)
Inventory turnover ratio; and
(ii)
the number of days for which the average inventory is held
Answer (i) Inventory turnover ratio 2.5
is held 146 days
22
(ii)
the number of days for which the average inventory
M/s Tubes Ltd. are the manufacturers of picture tubes for T.V. The following are the details of their
operation during 1997:
Average monthly market demand
2,000 Tubes
Ordering cost
` 100 per order
Inventory carrying cost
20% per annum
Cost of tubes
` 500 per tube
Normal usage
100 tubes per week
Minimum usage
50 tubes per week
Maximum usage
200 tubes per week
Lead time to supply
6-8 weeks
Compute from the above:
(1)
Economic Order Quantity. If the supplier is willing to supply quarterly 1,500 units at a discount of 5%,
is it worth accepting?
(2)
Maximum level of stock
(3)
Minimum level of stock
(4)
Reorder level
© The Institute of Chartered Accountants of India
Materials
2.47
Answer (1) Economic Order Quantity102 tubes (approx.)
The offer should be accepted
23
(2)
Maximum level of stock 1,402 units.
(3)
Minimum level of stock 900 units.
(4)
Reorder level 1,600 units
If the minimum stock level and average stock level of raw-material A are 4,000 and 9,000 units respectively,
find out its 'Re-order quantity'
Answer Re-order quantity = 10,000 units.
24
At what price per unit would Part No. A32 be entered in the Stores Ledger, if the following invoice was
received from a supplier:
Invoice
200 units Part No. A32 @ ` 5
Less: 20% discount
`
1,000.00
200.00
800.00
120.00
920.00
50.00
970.00
Add: Excise Duty @ 15%
Add Packing charges (5 non-returnable boxes)
Notes:
(i)
A 2 percent discount will be given for payment in 30 days.
(ii)
Documents substantiating payment of excise duty is enclosed for claiming MODVAT credit.
Answer
25
In a company weekly minimum and maximum consumption of material A are 25 and 75 units respectively.
The re-order quantity as fixed by the company is 300 units. The material is received within 4 to 6 weeks
from issue of supply order. Calculate Minimum level and maximum level of material A.
Answer
26
Cost per unit = ` 4.25
Minimum level = 200 units
Maximum level = 600 units
JP Limited, manufacturers of a special product, follows the policy of EOQ (Economic Order Quantity) for
one of its components. The component's details are as follows:
`
Purchase Price Per Component
Cost of an Order
Annual Cost of Carrying one Unit in Inventory
Total Cost of Inventory and Ordering Per
Annum
200
100
10% of Purchase Price
4,000
The company has been offered a discount of 2% on the price of the component provided the lot size is
2,000 components at a time.
You are required to:
(a)
Compute the EOQ
(b)
Advise whether the quantity discount offer can be accepted.
© The Institute of Chartered Accountants of India
2.48
Cost Accounting
(Assume that the inventory carrying cost does not vary according to discount policy)
(c)
Would your advice differ if the company is offered 5% discount on a single order?
Answer (a) E.O.Q. = 200 units
27
(b)
The offer should not be accepted
(c)
The offer should be accepted
From the details given below, calculate
(i)
Re-ordering level
(ii)
Maximum level
(iii)
Minimum level
(iv)
Danger level
Re-ordering quantity is to be calculated on the basis of following information:
Cost of placing a purchase order is ` 20
Number of units to be purchased during the year is 5,000.
Purchase price per unit inclusive of transportation cost is ` 50.
Annual cost of storage per unit is ` 5.
Details of lead time:
Average 10 days, Maximum 15 days, Minimum 6 days.
For emergency purchases 4 days.
Rate of consumption:
Answer
28
Re-ordering level = 300 units
(ii)
Maximum level = 440 units
(iii)
Minimum level = 150 units
(iv)
Danger level = 60 units
Write short notes on ABC Analysis
Answer
29
(i)
Average: 15 units per day, Maximum : 20 units per day.
Refer to ‘Chapter No. 2 i.e. Material’ of Study Material
The following information is extracted from the Stores Ledger:–
Material X
Opening Stock
Nil
Purchases :
Jan.1 100 @ ` 1 per unit
Jan. 20
100 @ ` 2 per unit
Issues:
Jan. 22
60 for Job W 16
Jan 23
60 for Job W 17
© The Institute of Chartered Accountants of India
Materials
2.49
Complete the receipts and issues valuation by adopting the First-in First-Out, Last-in First Out and the
Weighted Average Method. Tabulate the values allocated to Job W 16, Job W 17 and the closing stock
under the methods aforesaid and discuss from the different points of view which method you would prefer.
Answer
Closing Stock (`)
30
FIFO
LIFO
Weighted Average
160
80
120
AT Ltd. furnishes the following stores transactions for September, 1982
1-9-82
Opening balance
4-9-82
Issues Req. No. 85
25 Units value ` 162.50
8 Units
6-9-82
Receipts from B & Co. GRN NO. 26
50 Units @ ` 5.75 per unit
7-9-82
Issues Req. No. 97
12 Units
10-9-82
Returns to B & Co.
10 Units
12-9-82
Issues Req. No. 108
15 Units
13-9-82
Issues Req. No.110
20 Units
15-9-82
Receipts from M & Co. GRN NO. 33
25 Units @ ` 6.10 per unit
17-9-82
Issues Reg. No. 121
10 Units
19-9-82
Received replacement from B & Co. GRN No. 38
10 Units
20-9-82
Returned from department material of M & Co. MRR No.4
5 Units
22-9-82
Transfer from Job 182 to Job 187 in the dept. MTR 6
5 Units
26-9-92
Issues Req. No. 146
29-9-82
Transfer from Dept. "A" to Dept. "B" MTR 10
5 Units
30-9-82
Shortage in stock taking
2 Units
10 units
Write up the priced stores ledger on FIFO method and discuss how would you treat the shortage in stock
taking.
Answer
31
Balance ` 167.30
A manufacturer of Surat purchased three Chemicals A, B and C from Bombay. The invoice gave the
following information:
`
Chemical A :
3,000 kg @ ` 4.20 per kg.
12,600
Chemical B: 5,000 kg @ ` 3.80 per kg.
19,000
Chemical C: 2,000 kg. @ ` 4.75 per kg.
9,500
Sales Tax
2,055
Railway Freight
Total Cost
1,000
44,155
A shortage of 200 kg in Chemical A, of 280 kg. in Chemical B and of 100 kg. in Chemical C was noticed due
to breakages. At Surat, the manufacturer paid Octroi duty @ ` 0.10 per kg. He also paid Cartage ` 22 for
Chemical A, ` 63.12 for Chemical B and ` 31.80 for Chemical C. Calculate the stock rate that you would
suggest for pricing issue of chemicals assuming a provision of 5% towards further deterioration.
© The Institute of Chartered Accountants of India
2.50
Cost Accounting
Answer
Rate of issue per Kg
32
A
B
C
`5.20
` 4.68
` 5.76
Shriram Enterprises manufactures a special product "ZED". The following particulars were collected for the
year 1986:
(a)
Monthly demand of ZED-1,000 units.
(b)
Cost of placing an order ` 100.
(c)
Annual carrying cost per unit ` 15.
(d)
Normal usage 50 units per week
(e)
Minimum usage 25 units per week.
(f)
Maximum range 75 units per week
(g)
Re-order period 4 to 6 weeks.
(3)
Minimum Level
Compute from the above
(1)
Re-order Quantity (2)
(5)
Average Stock Level
Re-order level
(4)
Maximum Level
Answer (1) Re-order Quantity= 186 units
33
(2)
Re-order level = 450 units
(3)
Minimum Level = 200 units
(4)
Maximum Level = 536 units
(5).
Average Stock Level= 368 units
(a)
What is Economic Order Quantity?
Answer Refer to ‘Chapter No.2 i.e. Material’ of Study Material
(b)
The Purchase Department of your organisation has received an offer of quantity discounts on its
order of materials as under:
Price per tonne
Tonnes
`
1,400
1,380
1,360
1,340
1,320
Less than 500
500 and less than 1,000
1,000 and less than 2,000
2,000 and less than 3,000
3,000 and above
The annual requirement of the material is 5,000 tonnes. The delivery cost per order is ` 1,200 and
the annual stock holding cost is estimated at 20 per cent of the average inventory.
The Purchase Department wants you to consider the following purchase options and advise which
among them will be the most economical ordering quantity, presenting the relevant information in a
tabular form.
The purchase quantity options to be considered are 400 tonnes, 500 tonnes, 1,000 tonnes, 2,000
tonnes and 3,000 tonnes
Answer
34
Most economical order size 1,000 tonnes
Component 'Pee' is made entirely in cost centre 100. Material cost is 6 paise per component and each
component takes 10 minutes to produce. The machine operator is paid 72 paise per hour, and the machine
hour rate is ` 1.50. The setting up of the machine to produce the component 'Pee' takes 2 hours 20
minutes.
© The Institute of Chartered Accountants of India
Materials
2.51
On the basis of this information, prepare a cost sheet showing the production and setting up cost, both in
total and per component, assuming that a batch of:
(a)
10 components,
(b)
100 components, and
Answer Components
Total Cost (`)
35
1,000 components is produced
10
100
1000
9.48
48.18
435.18
X Ltd. is committed to supply 24,000 bearings per annum to Y Ltd. on a steady basis. It is estimated that it
costs 10 paise as inventory holding cost per bearing per month and that the set-up cost per run of bearing
manufacture is ` 324.
(a)
What would be the optimum run size for bearing manufacture?
(b)
Assuming that the company has a policy of manufacturing 6,000 bearing per run, how much extra
costs the company would be incurring as compared to the optimum run suggested in (a) above?
(c)
What is the minimum inventory holding cost?
Answer
(c)
36
(c)
(a)
3,600 bearings.
(b)
Extra Cost incurred = ` 576
Minimum inventory holding cost = ` 2,160
Raw materials 'X' costing ` 100 per kilogram and 'Y’ costing ` 60 per kilogram are mixed in equal
proportions for making product 'A'. The loss of material in processing works out to 25% of the output. The
production expenses are allocated at 50% of direct material cost. The end product is priced with a margin of
33 1 % over the total cost. Material 'Y' is not easily available and substitute raw material 'Z' has been found
3
for 'Y’ costing ` 50 per kilogram. It is required to keep the proportion of this substitute material in the
mixture as low at possible and at the same time maintain the selling price of the end product at existing
levels and ensure the same quantum of profit as at present.
You are required:
To compute what should be the ratio of mix of the raw materials X and Z.
Answer
The ratio of mix of the raw materials X and Z =3:2.
37 SK Enterprise manufactures a special product “ZE”. The following particulars were collected for the year 2004:
Annual consumption
12,000 units (360 days)
Cost per unit
`1
Ordering cost
` 12 per order
Inventory carrying cost
24%
Normal lead time
15 days
Safety stock
30 days consumption
Required:
(i)
Re-order quantity
(ii)
Re-order level
(iii)
What should be the inventory level (ideally) immediately before the material order is received?
Answer
(i)
Re-order quantity = 1095.4 units or say 1,100 units
© The Institute of Chartered Accountants of India
2.52
38
Cost Accounting
(ii)
Re-order level = 1,500 units
(iii)
The inventory level (ideally) immediately before the material order is received = 1,000
units.
PQR Limited produces a product which has a monthly demand of 52,000 units. The product requires a
component X which is purchased at ` 15 per unit. For every finished product, 2 units of Component X are
required. The Ordering cost is ` 350 per order and the Carrying cost is 12% p.a.
Required:
(i)
Calculate the economic order quantity for Component X.
(ii)
If the minimum lot size to be supplied is 52,000 units, what is the extra cost, the company has to
incur?
(iii)
What is the minimum carrying cost, the Company has to incur?
Answer
39
economic order quantity = 15,578 units of components
(ii)
Extra cost incurred = ` 22,960
(iii)
Minimum carrying cost = ` 14,020
The rate of interest is 12%, the price per unit is ` 50, the number of units required in a year is 5,000 and the cost
of placing one order and receiving the goods once is ` 54. How much should be purchased at a time ?
Answer
40
(i)
300 units
The following is the record of an item in a stores ledger
Units
Amount
Units
`
To Balance b/d
To Purchase
To Purchase
To Purchase
Answer
(i)
`
10,000
20,000
Jan. 15
By Issue
14,000
30,000
5,000
12,000
Feb. 8
By Issue
6,000
15,000
20,000
55,000
Mar. 15 By Issue
22,000
60,000
10,000
30,000
Mar. 31 By Bal. C/d
3,000
12,000
45,000
1,17,000
45,000
1,17,000
Comment upon the method followed to price the issues. Find out the value of closing stock assuming issue
to have been made for period on (i) FIFO basis, (ii) LIFO basis, and (iii) Weighted average basis.
41
Jan. 1
Jan. 10
Feb. 3
Mar. 10
Amount
` 9,000
(ii)
` 7,500
(iii)
` 8,497
A company ordered 54 tonnes of coal from a colliery. The invoice was for ` 1,000, the freight being ` 300.
The actual quantity received was 52 tonnes. What should be the price per tonne ?
Ten tonnes of coal were destroyed by an accident quantity received was 52 tonnes. How should be the loss
be treated?
Answer
42
` 25; Debit Costing Profit and Loss A/c ` 250.
In a section of ready-made garments factory the monthly wages and overhead respectively amounted to
` 5,875 and ` 3,650. In a period 10,000 metres of cloth were introduced out of which 600 metres still remained in
stock. It takes 2 metres to make the garments but in the month, the total output was 4,500 garments. The cost of
the cloth is ` 3.50 per metre. Ascertain the cost of garment, assuming cuttings were sold for ` 125.
Answer
Cost ` 9.09 per unit; loss debited to Costing Profit and Loss A/c 1,400.
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