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Question

Objectives:

1.         Apply accounting manufacturing concepts to an actual product to solidify the learning process.

2.         Learn how all the numbers fit together.

3.         Develop decision making analysis techniques.

Manufacturing Questions Instructions:

1. This project should stand by itself.  Include the questions with your submission--not just the answers.  Identify all numbers.  Points will be deducted if I can't understand what you are answering.
2. You may use Excel to complete tables and/or answer questions.  Just make sure you label your work and turn the Excel file in.
3. You may discuss this project with classmates.  A discussion board will be set up for this project.  Try to get help from classmates first.  Your professor will only provide limited individual help. 

Your information:

1. Your company produces a basic potato chip. There are three main processes used in the chips.  The first process washes and peels the potatoes.  The second process slices and fries the potatoes.  The third process seasons and packages the chips.  The potato chips are sold in 12 oz bags (1 bag is a unit)

1. Information on the direct materials is listed in table 1. Consider this information the standard.  

1.  Direct labor information given in Table 2.  Consider this information the standard. 

1. Annual overhead information is given in Table 3. Overhead is allocated based direct labor hours.  Estimated annual direct labor hours are 12,500.  Calculate a predetermined OH rate (round to two decimal places if needed).  Use this rate when you need to apply OH.

1. Table 4 gives you the information for the last two months on the overhead cost.  Use this information to determine the fixed and variable portions of the cost.  (You will need this information to complete Table 5). Machine hours have been determined as the best cost driver for separating mixed cost into their fixed and variable portions. It takes approximately 12 minutes of total machine time for each bag of chips (or 1/5 a machine hour per bag of chips).

1. Table 5 is where you will list all your production cost, separated into their fixed and variable components.

1. Cost-Volume-Profit (CVP) Relationships

a.    Selling Price:  You sell a bag of chips for $4.00

b.   Breakeven point: Calculate the breakeven point.   Be sure to include the fixed component of mixed cost in your fixed costs and the variable component in the         variable cost.  Show your breakeven in Sales units and in Sales Dollars

c.    Profit Planning:  Determine the number of units you must sell to make an annual pre-tax profit using 3 assumptions concerning your net income (profit), both in sales units and sales dollars.

                                                              i.      Aggressive Profit ($100,000)

 

                                                            ii.      Conservative Profit ($25,000)

 

                                                          iii.      Average Profit ($60,430)

1. Budgeting: 

a.                   Create a sales budget using the information for earning an average profit for the year.  You will break the budget down into the four quarters for the year. (Sales tend to be consistent each quarter, you can only sale a whole unit so round-up if necessary) Use table 6 to complete the sales budget.

b.                  Create a production budget for each quarter of the year (keep it in quarters; you do not need to break it down by month).  You desire to keep 10% of next quarter's sales in ending inventory.  Sales for Qtr 1 the following year are expected to be 30,000 bags of chips. There is not any beginning finished goods inventory for quarter one. Use table 7 to complete the production budget.

1. Running quarter one -- Weighted-average process costing.  Table 8 presents the information for the packaging department.  Complete the questions under table 8.

1. Actuals are in for quarter one.  You sold 25% more units than you budgeted for, but price per unit was only $3.80.

a.                   Calculate revenue

b.                  Compute the cost of goods sold (total and per unit) before adjusting for actual OH cost

1. Actual potato usage for quarter one was 68,000 pounds at a price of $0.45 per pound. Actual equivalent units of production (bags of chips) completed through the fist process (where the potatoes are added) was 29,520.  Calculate the direct materials variances for the potatoes (price, usage, and total) and indicate if these variances are favorable or unfavorable.

1. Actual direct labor hours for the quarter were 4,830 at an average rate of $8.10 per hour.  For actual production you expected to use 4,200 direct labor hours.  Calculate the direct labor variances (rate, efficiency and total) and indicate if these variances are favorable or unfavorable. 

1. For next quarter you have been asked to supply a special order of you potato chips.  The non-profit organization requesting this order would like a special bag that will cost $0.20 instead of the normal $0.10 per bag.  The request is for 10,000 bags of chips.  Based on your projections you have the capacity for this order.  What is the minimum price per unit and total price you would be willing to accept on this order?  (You cannot afford to take this offer at a loss, but you are fine with accepting it at cost).

1. Determine over- or under-applied overhead and close to cost of goods sold.  Actual OH cost are given in table 14 (look at #12 for actual DL hours used to apply OH).  Determine the new cost of goods sold amount. 

Table 1: Direct Materials

Material                Quantity            Cost           Total                                                                      per unit                                   per unit                                  

Potatoes	1.5 lbs	$0.50	$0.75
Seasoning	0.1 ounces	$0.50	$0.05
Packaging	1 bag	$0.10	$0.10
	1/12 box	$0.48	$0.04
TOTAL			$0.94

Table 2:   Direct Labor

 

                                                    Hours                        

                                                   Per Bag

Job Description                         of chips             Rate           Total Cost

Potato Washer  & Peeler	.1	$8.00	$0.80
Slicer & Fryer	.04	$8.00	$0.32
Packager	.05	$8.00	$0.40
Total	0.14		$1.52

 

Table 3:  YEARLY OVERHEAD  COSTS

          Cost  Description                                      Total Cost                             

Indirect Materials	$6,000
Indirect Labor	60,010
Machine Maintenance	4,040
Electricity	3,440
Depreciation	4,680
Quality Testing	10,160
TOTAL	$88,330

 

Predetermined OH rate:

Table 4 - Actual Overhead cost for the last two months

 

	Month 1	Month 2
Indirect Material	$500	$500
Indirect Labor	$5000.83	$5000.83
Machine Maintenance	$250	$290
Electricity	$200	$240
Depreciation	$390	$390
Quality Testing	$630	$730
Machine Hours*	1000	1200

*12 minutes of machine time per bag of chips (1/5 hour = 1 unit)

 

 Complete any calculations here:

 

 

 Table 5:  Variable and Fixed Costs

 

COSTS Description                  VARIABLE Cost per unit                    FIXED Cost per Year           

TOTAL

If a cost is mixed, put the fixed amount in the fixed column and the variable amount in the variable column.

 

CVP Calculations:

 

 

Table 6 - Sales Budget

	Qtr 1	Qtr 2	Qtr 3	Qtr 4	Total

 

Table 7 - Production Budget

	Qtr 1	Qtr 2	Qtr 3	Qtr 4

 

 

Process Costing - Packaging Department

 

Direct materials are added 70% at the beginning of the process and the remaining 30% are added when the chips are 50% complete with the packaging process.  Direct labor and overhead are added evenly throughout the process.

 

Table 8 - Unit and cost information

		Cost
	Physical Units	Transferred-in	Direct Materials	Direct Labor	Overhead
Beg WIP	1,000 (40% complete)	$5,550	$110.40	$165	$141.44
Transferred In	30,000	$73,500
End WIP	2,200 (30% complete)

 

Added during Qtr 1:

Direct Materials -- $4,835.02

Direct Labor - 1,580 hrs @ $8.10 per hour

Overhead - OH is applied based on predetermined OH rate and actual DL hours

1. Determine the number of units completed during quarter 1.

2. Compute the equivalent units using the weighted average method

3. Compute the cost per equivalent unit using the weighted average method

4. Compute the cost of goods transferred to finished goods inventory

5. Compute the ending balance in WIP, Packaging

Table 10 - Actual Results (calculate revenue and COGS)

Units sold	Sales Price	Revenue
Units sold	Cost per unit	COGS

 

Table 11 - DM Variances (potatoes only)

Price Variance
Usage Variance
Total Variance

 

Calculations:

Table 12 - Direct Labor Variances

Rate Variance
Efficiency Variance
Total Variance

Calculations:

#13 Calculations (Minimum price on special order)

Table 14 - Actual OH cost for Quarter 1

Description	Cost
Indirect Materials	$1,750
Indirect Labor	$15,000
Machine Maintenance	$1,416.20
Electricity	$1,235.75
Depreciation	$1,050
Quality Testing	$4,615

 

Amount of applied OH:Amount of actual OH:

Under or Over- Applied Amount:

New COGS amount: