ac 505 chapter 2 power point slides
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McGraw-Hill/Irwin Slide 1
TCO A - Given a trial balance of a manufacturing entity, prepare a schedule ofcost of goods manufactured and an income statement.
Key Concepts:•Construct and use a Cost of Goods Manufactured schedule.•Define and apply cost concepts classifications and behaviors.
TCO E - Given appropriate financial data, prepare income statements usingdirect/variable costing, full cost/absorption costing, and activity basedcosting, including a discussion of the uses of each.
Key Concepts:•Describe the uses and users of the Income Statement. Define and apply costconcepts classifications and behaviors.
Week 1
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© 2010 The McGraw-Hill Companies, Inc.
2
The primary purpose of the Trial Balance is to prove themathematical equality of debits and credits.
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3
Balance as Oct. 31 fromRetained Earnings Statement
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© 2010 The McGraw-Hill Companies, Inc.
Managerial Accounting
and Cost ConceptsChapter 2
•Differences and similarities between financial and managerial accounting•Explains how managers need to rely upon different classifications of costs for different purposes.•Emphasis include preparing external financial reports, predicting cost behavior, assigning coststo cost objects, and making business decisions.
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McGraw-Hill/Irwin Slide 5
Work of Management
Planning
Controlling
Directing andMotivating
Management focuses on planning and control to ensure that objectives arerealized. To carry out these planning and control responsibilities, managers needinformation about the organization. From an accounting point of view, thisinformation often relates to the costs of the organization.
Managers carry out three main activities – planning, directing andmotivating, and controlling.
Involves establishing a basic strategy, selectinga course of action, and specifying how the
action will be implemented.
Involves mobilizing people tocarry out plans and run routineoperations.
Involves ensuring that the plan is actuallycarried out and is appropriately modified as
circumstances change.
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Learning Objective 1
Identify the majordifferences and similarities
between financial andmanagerial accounting.
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Comparison of Financial and ManagerialAccounting
Financial Accounting Managerial Accounting1. Users External persons who Managers who plan for
make financial decisions and control an organization
2. Time focus Historical perspective Future emphasis
3. Verifiability Emphasis on Emphasis on relevanceversus relevance verifiability for planning and control
4. Precision versus Emphasis on Emphasis ontimeliness precision timeliness
5. Subject Primary focus is on Focuses on segments
the whole organization of an organization
6. GAAP Must follow GAAP Need not follow GAAPand prescribed formats or any prescribed format
7. Requirement Mandatory for Notexternal reports Mandatory
GAAP includes the standards, conventions, and rules accountants follow in recordingand summarizing transactions, and in the preparation of financial statements .
MA aids decisionmakers byproviding goodestimates ASAP
When reporting to external parties
Product lines, sales territories, divisions, departments
Data should be objective & verifiable Data should be appropriate at hand.
Based on estimates of what will happen.
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Learning Objective 2
Identify and give examplesof each of the three basic
manufacturing costcategories.
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The Product
DirectMaterials
DirectLabor
ManufacturingOverhead
Manufacturing CostsManufacturing costs are usually grouped into three main categories: direct materials, direct labor, and
manufacturing overhead. These costs are incurred to make a product.
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Direct Materials
Raw materials that become an integralpart of the product and that can beconveniently traced directly to it.
Example: A radio installed in an automobile, the seats that Airbus purchasesfrom subcontractors to install in its commercial aircraft.
Raw materials refer to any materials that are used in the final product; and the finished productof one company can become the raw material of another company. For example, the plasticsproduced by Du Pont are a raw material used by Compaq Computer in its personal computer.
Raw materials may include both direct materials and indirect materials. Direct materials are those materials thatbecome an integral part of the finished product and whose cost can be conveniently traced to the finishedproduct. Indirect materials are those not worth the effort of tracing the cost to a product because of relatively
insignificant materials to end products and should be included as part of manufacturing overhead .
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Direct Labor
Those labor costs that can be easilytraced to individual units of product.
Example: Wages paid to automobile assembly workers
It is sometimes called touch labor because direct labor workers
typically touch the product while it is being made.
Labor costs that cannot be physically traced to particular products, or that can be traced only at great cost andinconvenience, are termed indirect labor and should be treated as part of manufacturing overhead , e.g. Janitors, Night
Security.
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Nonmanufacturing Costs
SellingCosts
Costs necessary to
secure the order anddeliver the product.
AdministrativeCosts
All executive,
organizational, andclerical costs.
Other costs incurred in addition tomanufacturing costs.
Examples include advertising, shipping, sales travel,sales commissions, sales salaries, and costs of finishedgoods warehouses .
Examples include executive compensation, generalaccounting, secretarial, public relations, and similarcosts involved in the overall general administration ofthe organization as a whole.
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Learning Objective 3
Distinguish betweenproduct costs and period
costs and give examplesof each.
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Product Costs Versus Period Costs
Product costs includedirect materials, direct
labor, andmanufacturing
overhead .
Period costs include allselling costs and
administrative costs.
Inventory Cost of Good Sold
BalanceSheet
IncomeStatement
Sale
Expense
IncomeStatement
Costs incurred to produce a product or service.
Inventoriable costs because it goesdirectly into inventory accounts asthey’re incurred. Hence, costs canend up on the B/S as assets if goodsare only partially completed or areunsold at the end of the period.
As goods are sold, their costsare transferred from FinishedGoods to COGS (expenseaccount) which is consistentwith Matching Principle – product costs are recognized asexpenses when the productsare sold.
Costs that go directly into expense account.
Costs can also be classified as -
The usual rules of accrual accounting apply toperiod costs. For example, administrative salary
costs are “incurred” when they are earned by theemployees and not necessarily when they are paid
to employees .
Matching principle is based on the accrual concept that costs incurred to generate a particular revenue should be recognized as expenses in the same period that the revenue is recognized . For example, if a company pays for liability
insurance in advance for two years, the entire amount is not considered an expense of the year in which payment ismade. Instead, one-half of the cost would be recognized an expense each year.
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Quick Check
Which of the following costs would be considered aperiod rather than a product cost in a manufacturingcompany?
A. Manufacturing equipment depreciation.B. Property taxes on corporate headquarters.C. Direct materials costs.D. Electrical costs to light the production
facility.E. Sales commissions.
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Quick Check
Which of the following costs would be considered aperiod rather than a product cost in a manufacturingcompany?
A. Manufacturing equipment depreciation.B. Property taxes on corporate headquarters.C. Direct materials costs.D. Electrical costs to light the production
facility.E. Sales commissions.
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Classifications of Costs
DirectMaterial
DirectLabor
ManufacturingOverhead
PrimeCost
ConversionCost
Manufacturing costs are oftenclassified as follows:
Costs that are the directcosts of production.
Costs that are composed of itemsinvolved in the conversion of the
materials into the product.
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Comparing Merchandising andManufacturing Companies
Merchandisers . . .Buy finishedgoods.Sell finishedgoods.
Manufacturers . . .Buy raw materials.Produce and sellfinished goods.
MegaLoMart
Cost Classifications onFinancial Statements.
Just one class of inventory Three classes of inventories
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Balance Sheet
MerchandiserCurrent assets
Cash
ReceivablesMerchandise Inventory
ManufacturerCurrent Assets
Cash
ReceivablesInventories
• Raw Materials• Work in Process
• Finished Goods
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MerchandiserCurrent assets
Cash
ReceivablesMerchandise Inventory
ManufacturerCurrent Assets
Cash
ReceivablesInventories
• Raw Materials• Work in Process
• Finished Goods
Balance Sheet
Partially completeproducts – somematerial, labor, or
overhead has beenadded.Completed products
awaiting sale.
Materials waiting tobe processed.
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McGraw-Hill/Irwin Slide 23
The Income Statement
Cost of goods sold for manufacturers differs onlyslightly from cost of goods sold for merchandisers.
Manufacturing Company
Cost of goods sold:Beg. finishedgoods inv. 14,200$
+ Cost of goodsmanufactured 234,150
Goods available
for sale 248,350$- Ending
finished goodsinventory (12,100)
= Cost of goodssold 236,250$
Merchandising Company
Cost of goods sold:Beg. merchandise
inventory 14,200$+ Purchases 234,150 Goods available
for sale 248,350$
- Endingmerchandiseinventory (12,100)
= Cost of goodssold 236,250$
Themanufacturing
costsassociated
with thegoods that
were finishedduring the
period.
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McGraw-Hill/Irwin Slide 24
Basic Equation for Inventory Accounts
Beginningbalance
Additionsto inventory+ =
Endingbalance
Withdrawalsfrom
inventory
+
The computation of Cost of Goods Sold relies on this basic equation forinventory accounts.
3 units 4 units
Total available = 7 units – 3 units of Withdrawals = 4 units Ending balance
3 units4 units
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McGraw-Hill/Irwin Slide 25
Quick Check
If your inventory balance at the beginning of themonth was $1,000, you bought $100 during themonth, and sold $300 during the month, what wouldbe the balance at the end of the month?A. $1,000.B. $ 800.C. $1,200.
D. $ 200.
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McGraw-Hill/Irwin Slide 26
Quick Check
If your inventory balance at the beginning of themonth was $1,000, you bought $100 during themonth, and sold $300 during the month, what wouldbe the balance at the end of the month?A. $1,000.B. $ 800.C. $1,200.
D. $ 200.
$1,000 + $100 = $1,100$1,100 - $300 = $800
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McGraw-Hill/Irwin Slide 27
Learning Objective 5
Prepare a schedule of costof goods manufactured.
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Schedule of Cost of Goods Manufactured
Calculates the cost of rawmaterial, direct labor, andmanufacturing overhead
used in production.
Calculates the manufacturingcosts associated with goodsthat were finished during the
period.
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McGraw-Hill/Irwin Slide 29
Manufacturing WorkRaw Materials Costs In Process
Beginning raw Direct materialsmaterials inventory
+ Raw materialspurchased= Raw materials
available for usein production
– Ending raw materials
inventory= Raw materials used
in production
As items are removed from rawmaterials inventory and placed into
the production process, they arecalled direct materials.
Product Cost FlowsTo create a schedule of cost of goods manufactured, as well as a balance sheet and income statement, it
is important to understand the flow of product costs.
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Manufacturing WorkRaw Materials Costs In Process
Beginning raw Direct materialsmaterials inventory + Direct labor
+ Raw materials + Mfg. overheadpurchased = Total manufacturing= Raw materials costs
available for usein production
– Ending raw materials
inventory= Raw materials used
in production
Conversioncosts are costs
incurred toconvert the
direct materialinto a finished
product.
Product Cost Flows
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McGraw-Hill/Irwin Slide 31
Manufacturing WorkRaw Materials Costs In Process
Beginning raw Direct materials Beginning work inmaterials inventory + Direct labor process inventory
+ Raw materials + Mfg. overhead + Total manufacturingpurchased = Total manufacturing costs= Raw materials costs = Total work in
available for use process for thein production period
– Ending raw materials
inventory= Raw materials used
in production
Product Cost Flows
All manufacturing costs incurredduring the period are added to thebeginning balance of work in
process.
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McGraw-Hill/Irwin Slide 32
Manufacturing WorkRaw Materials Costs In Process
Beginning raw Direct materials Beginning work inmaterials inventory + Direct labor process inventory
+ Raw materials + Mfg. overhead + Total manufacturingpurchased = Total manufacturing costs= Raw materials costs = Total work in
available for use process for thein production period
– Ending raw materials – Ending work in
inventory process inventory= Raw materials used = Cost of goods
in production manufactured
Product Cost Flows
Costs associated with the goods thatare completed during the period are
transferred to finished goodsinventory.
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McGraw-Hill/Irwin Slide 33
WorkIn Process Finished Goods
Beginning work in Beginning finished
process inventory goods inventory+ Manufacturing costs + Cost of goodsfor the period manufactured
= Total work in process = Cost of goodsfor the period available for sale
– Ending work in - Ending finishedprocess inventory goods inventory
= Cost of goods Cost of goodsmanufactured sold
Product Cost Flows
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Manufacturing Cost Flows
FinishedGoods
Cost ofGoods
Sold
Selling andAdministrative
Period CostsSelling andAdministrative
ManufacturingOverhead
Work inProcess
Direct Labor
Balance SheetCosts Inventories
IncomeStatementExpenses
Material Purchases Raw Materials
At the end ofthe period.
RM used in production WP can be viewed asproduct on an assembly line.
The RM, DL, and MO areadded to WP are the costsneeded to complete these
products as they move alongthe assembly line.
Product costs are often called inventoriable costs because thesecosts go directly into inventory as they are incurred, rather than
expense accounts. This is a key concept because such costs can end up on the balance sheet as asset if good are partially
completed or are unsold at the end of a period .
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McGraw-Hill/Irwin Slide 35
Quick Check
Beginning raw materials inventory was $32,000.During the month, $276,000 of raw material waspurchased. A count at the end of the month
revealed that $28,000 of raw material was stillpresent. What is the cost of direct materialused?
A. $276,000B. $272,000C. $280,000D. $ 2,000
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McGraw-Hill/Irwin Slide 36
Quick Check
Beginning raw materials inventory was $32,000.During the month, $276,000 of raw material waspurchased. A count at the end of the month
revealed that $28,000 of raw material was stillpresent. What is the cost of direct materialused?
A. $276,000B. $272,000C. $280,000D. $ 2,000
Beg. raw materials 32,000$+ Raw materials
purchased 276,000 = Raw materials available
for use in production 308,000$ – Ending raw materialsinventory 28,000
= Raw materials usedin production 280,000$
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McGraw-Hill/Irwin Slide 37
Quick Check
Direct materials used in production totaled$280,000. Direct labor was $375,000 andfactory overhead was $180,000. What were totalmanufacturing costs incurred for the month?
A. $555,000B. $835,000C. $655,000
D. Cannot be determined.
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McGraw-Hill/Irwin Slide 38
Direct materials used in production totaled$280,000. Direct labor was $375,000 andfactory overhead was $180,000. What were totalmanufacturing costs incurred for the month?
A. $555,000B. $835,000C. $655,000
D. Cannot be determined.Direct Materials 280,000$
+ Direct Labor 375,000 + Mfg. Overhead 180,000 = Mfg. Costs Incurred
for the Month 835,000$
Quick Check
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McGraw-Hill/Irwin Slide 40
Beginning work in process was $125,000.Manufacturing costs incurred for the monthwere $835,000. There were $200,000 ofpartially finished goods remaining in work inprocess inventory at the end of the month.What was the cost of goods manufacturedduring the month?
A. $1,160,000B. $ 910,000C. $ 760,000D. Cannot be determined.
Quick Check
Beginning work inprocess inventory 125,000$
+ Mfg. costs incurredfor the period 835,000
= Total work in processduring the period 960,000$
– Ending work inprocess inventory 200,000
= Cost of goodsmanufactured 760,000$
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McGraw-Hill/Irwin Slide 41
Quick Check
Beginning finished goods inventory was$130,000. The cost of goods manufactured forthe month was $760,000. And the endingfinished goods inventory was $150,000. Whatwas the cost of goods sold for the month?A. $ 20,000.B. $740,000.
C. $780,000.D. $760,000.
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McGraw-Hill/Irwin Slide 42
Quick Check
Beginning finished goods inventory was$130,000. The cost of goods manufactured forthe month was $760,000. And the endingfinished goods inventory was $150,000. Whatwas the cost of goods sold for the month?A. $ 20,000.B. $740,000.
C. $780,000.D. $760,000.
$130,000 + $760,000 = $890,000$890,000 - $150,000 = $740,000
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McGraw-Hill/Irwin Slide 43
Learning Objective 6
Understand thedifferences between
variable costs and fixedcosts.
Cost Classifications for Predicting Cost
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McGraw-Hill/Irwin Slide 44
Cost Classifications for Predicting CostBehavior
How a cost will react tochanges in the level ofactivity within therelevant range.
Total variable costs change when activitychanges.
Total fixed costs remainunchanged when activitychanges.
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McGraw-Hill/Irwin Slide 45
Variable Cost
Your total texting bill is based on howmany texts you send.
Number of Texts Sent
T o
t a l T e x
t i n g
B i l l
Varies in direct proportion to changes in the level of activity.
The activity can be expressed in many ways, such as units purchased, units sold, miles driven, beds occupied, lines ofprint, hours worked, etc. A good example of a variable cost is direct materials. The cost of direct materials used during a
period will vary, in total, in direct proportion to the number of units produced.
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McGraw-Hill/Irwin Slide 46
Variable Cost Per Unit
Number of Texts Sent
C o s
t P
e r
T e x
t S e n
t
The cost per text sent is constant at5 cents per text.
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McGraw-Hill/Irwin Slide 47
Fixed Cost
Your monthly contract fee for your cell phone is fixed forthe number of monthly minutes in your contract. The
monthly contract fee does not change based on the numberof calls you make.
Number of Minutes Used
Within Monthly Plan
M o n
t h l y C e
l l P h o n e
C o n
t r a c
t F e e
A fixed cost is a cost that remains constant, in total, regardless of changes in the level of activity. Unlike variable costs, fixedcosts are not affected by changes in activity. It doesn’t change for changes in activity that fall within the “ relevant range ”.
The relevant range is the range of activitywithin which the assumptions about variableand fixed costs are valid. See page 49 for
the sample problem.
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McGraw-Hill/Irwin Slide 48
Fixed Cost Per Unit
Number of Minutes Used
Within Monthly Plan
M o n t h
l y C e
l l P h o n e
C o n
t r a c
t F e e
Within the monthly contract allotment, the averagefixed cost per cell phone call made decreases as
more calls are made.
Cost Classifications for Predicting Cost
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McGraw-Hill/Irwin Slide 49
Cost Classifications for Predicting CostBehavior
Behavior of Cost (within the relevant range)
Cost In Total Per Unit
Variable Total variable cost changes Variable cost per unit remainsas activity level changes. the same over wide ranges
of activity.
Fixed Total fixed cost remains Average fixed cost per unit goesthe same even when the down as activity level goes up.
activity level changes.
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McGraw-Hill/Irwin Slide 50
Quick Check
Which of the following costs would be variablewith respect to the number of cones sold at aBaskins & Robbins shop? (There may be more
than one correct answer.)A. The cost of lighting the store.B. The wages of the store manager.C. The cost of ice cream.D. The cost of napkins for customers.
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McGraw-Hill/Irwin Slide 51
Quick Check
Which of the following costs would be variablewith respect to the number of cones sold at aBaskins & Robbins shop? (There may be more
than one correct answer.)A. The cost of lighting the store.B. The wages of the store manager.C. The cost of ice cream.D. The cost of napkins for customers.
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Learning Objective 7
Understand thedifferences between direct
and indirect costs.
A cost object is anything for which costdata are desired including products,
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Assigning Costs to Cost ObjectsDirect costs
Costs that can beeasily andconveniently traced
to a unit of productor other cost object.Examples: directmaterial and directlabor
Indirect costsCosts that cannot beeasily andconveniently traced
to a unit of productor other cost object.Example:manufacturingoverhead
customers, jobs, organizationalsubunits, etc. For purposes ofassigning costs to cost objects, costsare classified in two ways:
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McGraw-Hill/Irwin Slide 54
Learning Objective 8
Define and give examplesof cost classifications usedin making decisions:
differential costs,opportunity costs, andsunk costs.
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McGraw-Hill/Irwin Slide 55
Every decision involves a choicebetween at least twoalternatives.
Only those costs and benefitsthat differ between alternativesare relevant in a decision. Allother costs and benefits canand should be ignored.
Cost Classifications for Decision Making
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McGraw-Hill/Irwin Slide 56
Differential Cost and Revenue
Costs and revenues that differamong alternatives.
Example: You have a job paying $1,500 per month inyour hometown. You have a job offer in a neighboringcity that pays $2,000 per month. The commuting costto the city is $300 per month.
Differential revenue is: $2,000 – $1,500 = $500
Differential cost is: $300
A difference in revenues between twoalternatives.
A difference in costs between twoalternatives.
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McGraw-Hill/Irwin Slide 57
Opportunity Cost
The potential benefit that is givenup when one alternative is selectedover another.
Example: If you werenot attending college,you could be earning$15,000 per year.Your opportunity costof attending college forone year is $15,000.
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McGraw-Hill/Irwin Slide 58
Sunk Costs
Sunk costs have already been incurred and cannotbe changed now or in the future. These costs
should be ignored when making decisions.
Example: You bought an automobile that cost$10,000 two years ago. The $10,000 cost is sunkbecause whether you drive it, park it, trade it, or sellit, you cannot change the $10,000 cost.
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McGraw-Hill/Irwin Slide 59
Quick Check
Suppose you are trying to decide whether todrive or take the train to Portland to attend aconcert. You have ample cash to do either, but
you don’t want to waste money needlessly. Isthe cost of the train ticket relevant in thisdecision? In other words, should the cost of thetrain ticket affect the decision of whether you
drive or take the train to Portland?A. Yes, the cost of the train ticket is relevant.B. No, the cost of the train ticket is not relevant.
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McGraw-Hill/Irwin Slide 60
Quick Check
Suppose you are trying to decide whether todrive or take the train to Portland to attend aconcert. You have ample cash to do either, but
you don’t want to waste money needlessly. Isthe cost of the train ticket relevant in thisdecision? In other words, should the cost of thetrain ticket affect the decision of whether you
drive or take the train to Portland?A. Yes, the cost of the train ticket is relevant.B. No, the cost of the train ticket is not relevant.
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McGraw-Hill/Irwin Slide 61
Quick Check
Suppose you are trying to decide whether todrive or take the train to Portland to attend aconcert. You have ample cash to do either, but
you don’t want to waste money needlessly. Isthe annual cost of licensing your car relevant inthis decision?A. Yes, the licensing cost is relevant.
B. No, the licensing cost is not relevant.
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McGraw-Hill/Irwin Slide 62
Quick Check
Suppose you are trying to decide whether todrive or take the train to Portland to attend aconcert. You have ample cash to do either, but
you don’t want to waste money needlessly. Isthe annual cost of licensing your car relevant inthis decision?A. Yes, the licensing cost is relevant.
B. No, the licensing cost is not relevant.
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McGraw-Hill/Irwin Slide 63
Quick Check
Suppose that your car could be sold now for$5,000. Is this a sunk cost?A. Yes, it is a sunk cost.
B. No, it is not a sunk cost.
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McGraw-Hill/Irwin Slide 64
Quick Check
Suppose that your car could be sold now for$5,000. Is this a sunk cost?A. Yes, it is a sunk cost.
B. No, it is not a sunk cost.
Summary of the Types of Cost
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McGraw-Hill/Irwin Slide 65
Summary of the Types of CostClassifications
FinancialReporting
Predicting CostBehavior
Assigning Coststo Cost Objects
Making BusinessDecisions
Variable and Fixed Costs.
Direct and Indirect Costs. Differential, Opportunity and Sunk Costs.
Product and Period Costs
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© 2010 The McGraw-Hill Companies, Inc.
Further Classification of Labor Costs
Appendix 2A
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McGraw-Hill/Irwin Slide 67
Learning Objective 9
(Appendix 2A)Properly account for laborcosts associated with idletime, overtime, and fringe
benefits.
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McGraw-Hill/Irwin Slide 68
Idle Time
The labor costs incurredduring idle time are ordinarily
treated as manufacturingoverhead.
MachineBreakdowns
MaterialShortages
PowerFailures
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McGraw-Hill/Irwin Slide 69
Overtime
The overtime premiums for all factoryworkers are usually considered to be part
of manufacturing overhead.
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McGraw-Hill/Irwin Slide 70
Labor Fringe Benefits
Fringe benefits include employer paidcosts for insurance programs, retirement
plans, supplemental unemployment
programs, Social Security, Medicare,workers’ compensation, andunemployment taxes.
Some companiesinclude all of these
costs inmanufacturing
overhead.
Other companies treatfringe benefit
expenses of directlaborers as additional
direct labor costs.
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© 2010 The McGraw-Hill Companies, Inc.
Cost of Quality
Appendix 2B
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McGraw-Hill/Irwin Slide 72
Learning Objective 10
(Appendix 2B)Identify the four types ofquality costs and explain
how they interact.
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McGraw-Hill/Irwin Slide 73
Quality of Conformance
When the overwhelming majority of productsproduced conform to design specifications
and are free from defects.There are four broadcategories of quality costs:prevention costs, appraisalcosts, internal failure costs,and external failure costs.
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McGraw-Hill/Irwin Slide 74
Prevention and Appraisal Costs
PreventionCosts
Support activitieswhose purpose is toreduce the number of
defects
Appraisal CostsIncurred to identifydefective products
before the products areshipped to customers
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McGraw-Hill/Irwin Slide 75
Internal and External Failure Costs
Internal FailureCosts
Incurred as a result ofidentifying defects
before they are shipped
External FailureCosts
Incurred as a result ofdefective productsbeing delivered to
customers
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McGraw-Hill/Irwin Slide 76
Examples of Quality Costs
Prevention Costs• Quality training• Quality circles• Statistical process
control activities
Appraisal Costs• Testing and inspecting
incoming materials• Final product testing• Depreciation of testing
equipment
Internal Failure Costs• Scrap• Spoilage• Rework
External Failure Costs• Cost of field servicing andhandling complaints• Warranty repairs• Lost sales
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McGraw-Hill/Irwin Slide 77
Distribution of Quality Costs
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McGraw-Hill/Irwin Slide 78
Learning Objective 11
(Appendix 2B)Prepare and interpret a
quality cost report.
Year 2 Year 1
Quality Cost ReportFor Years 1 and 2
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McGraw-Hill/Irwin Slide 79
Quality costreports providean estimate ofthe financial
consequencesof the
company’s
current defectrate.
Amount Percent* Amount Percent*Prevention costs:
Systems development 400,000$ 0.80% 270,000$ 0.54%Quality training 210,000 0.42% 130,000 0.26%Supervision of prevention activities 70,000 0.14% 40,000 0.08%
Quality improvement 320,000 0.64% 210,000 0.42%Total prevention cost 1,000,000 2.00% 650,000 1.30%
Appraisal costs:Inspection 600,000 1.20% 560,000 1.12%Reliability testing 580,000 1.16% 420,000 0.84%Supervision of testing and inspection 120,000 0.24% 80,000 0.16%Depreciation of test equipment 200,000 0.40% 140,000 0.28%
Total appraisal cost 1,500,000 3.00% 1,200,000 2.40%
Internal failure costs:Net cost of scrap 900,000 1.80% 750,000 1.50%Rework labor and overhead 1,430,000 2.86% 810,000 1.62%Downtime due to defects in quality 170,000 0.34% 100,000 0.20%Disposal of defective products 500,000 1.00% 340,000 0.68%
Total internal failure cost 3,000,000 6.00% 2,000,000 4.00%
External failure costs:Warranty repairs 400,000 0.80% 900,000 1.80%Warranty replacements 870,000 1.74% 2,300,000 4.60%Allowances 130,000 0.26% 630,000 1.26%Cost of field servicing 600,000 1.20% 1,320,000 2.64%
Total external failure cost 2,000,000 4.00% 5,150,000 10.30%Total quality cost 7,500,000$ 15.00% 9,000,000$ 18.00%
* As a percentage of total sales. In each year sales totaled $50,000,000.
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McGraw-Hill/Irwin Slide 80
Quality Cost Reports in Graphic Form
$10
9
8
7
6
5
4
3
2
1 Appraisal
0 Prevention Prevention
1 2
Year
Q u a
l i t y C o s
t ( i n m
i l l i o n s
)
Appraisal
Internal
Failure
ExternalFailure
InternalFailure
ExternalFailure
20
18
16
14
12
10
8
6
4
2 Appraisal
0 Prevention Prevention
1 2
Year
Q u a l
i t y C o s
t a s a
P e r c e n
t a g e o
f S a
l e s
Appraisal
Internal
Failure
ExternalFailure
InternalFailure
ExternalFailure
Qualityreports
can alsobe
preparedin
graphicform.
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McGraw-Hill/Irwin Slide 81
Uses of Quality Cost Information
Help managers see thefinancial significance of
defects.
Help managers identifythe relative importanceof the quality problems.
Help managers seewhether their quality
costs are poorlydistributed.
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McGraw-Hill/Irwin Slide 82
Limitations of Quality Cost InformationSimply measuring andreporting quality cost
problems does not solvequality problems.
Results usually lagbehind quality
improvement programs.
The most importantquality cost, lost sales, is
often omitted fromquality cost reports.
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McGraw-Hill/Irwin Slide 83
ISO 9000 StandardsISO 9000 standards have becomeinternational measures of quality.
To become ISO 9000 certified, acompany must demonstrate:
1. A quality control system is in use, and thesystem clearly defines an expected level ofquality.
2. The system is fully operational and is
backed up with detailed documentation ofquality control procedures.
3. The intended level of quality is beingachieved on a sustained basis.