Project On Factory Overhead Variances Analysis
Project On Factory Overhead Variances Analysis
Project On Factory Overhead Variances Analysis
COST ACCOUNTING
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ACKNOWLEDGEMENT
We are really humble persons and would unable to complete this presentation without the help and grace of almighty Allah. We would like to acknowledge the efforts of our parents they made for our education and it is their continuous encouragement and support that we are able to complete our presentation successfully. We would like to acknowledge the efforts of our teacher Sir who provides us the opportunity to explore the nuts and bolts of Business Communications. Only that education deserves emphatically to be termed cultivation of the mind which teaches young people how to begin to think. (Mary Wollstonecraft)
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EXECUTIVE SUMMARY
This project is related with standard cost and variances shown by these cost and the organization we chose for this matter is Bata shoe because it is also concern with manufacturing concern material, labor and FOH. As there is actual and standard cost set by the organization and these cost set by the organization and these cost changes with time and does not remain same. As Bata shoe is one of the larger manufacture of shoe in Pakistan and they provide and produce shoe foe each type of person for earning more and more customer. The cost of producing and product are changes with time and it does not remain same and the variances shown in the cost.
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Table of Contents
Introduction .......................................................................................... 5 Factory Overhead Variance ................................................................ 5 Factory overhead variance formulas ................................................ 17 Introduction to Organization ............................................................ 18 Brief history of Organization ............................................................. 18 Significance of the issue ................................................................... 19 PRACTICAL STUDY ........................................................................... 21 SWOT Analysis ................................................................................... 24 Data Collection Methods.................................................................... 25 SUGGESTIONS / RECOMMENDATIONS ........................................... 26 CONCLUSION ........................................................................... 26
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accounting objective is no different than observed for direct material and direct labor! On the left-hand side of the following graphic, notice that more is spent on actual variable factory overhead than is applied based on standard rates. This scenario produces unfavorable variances (also known as "underapplied overhead" since not all that is spent is applied to production). The right-hand side is the opposite scenario (favorable/overapplied overhead). Beneath the graphics are T-accounts intending to illustrate the cost flow. As monies are spent on overhead (wages, utilization of indirect materials, etc.), the cost (xxx) is transferred to the Factory Overhead account. As production occurs, overhead is applied/transferred to Work in Process (yyy). When more is spent than applied (as on the left scale), the balance (zz) is transferred to variance accounts representing the unfavorable outcome. When less is spent than applied (as on the right scale), the balance (zz) represents the favorable overall variances.
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The total variable overhead variance is unfavorable $3,000 ($102,000 $105,000). This may lead to the conclusion that performance is about on track. But, a closer look reveals that overhead spending was quite favorable,
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while overhead efficiency was not so good. Remember that 12,500 hours were actually worked. Since variable overhead is consumed at the presumed rate of $10 per hour, this means that $125,000 of variable overhead (actual hours X standard rate) was attributable to the output achieved. Comparing this figure ($125,000) to the standard cost ($102,000) reveals an unfavorable variable overhead efficiency variance of $23,000. However, this inefficiency was significantly offset by the $20,000 favorable variable overhead spending variance ($105,000 vs. $125,000). The following diagram may prove useful in helping you sort out the variable overhead variances:
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8-31-XX Work in Process Inventory Variable Overhead Efficiency Variance Variable OH Spending Variance Factory Overhead To increase work in process for the standard variable overhead, and record the related efficiency and spending variances
102,000 23,000
20,000 105,000
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How important is control of overhead? A study of self-made 50-year old millionaires revealed very little correlation between wealth and income, and a strong correlation between wealth and life-long savings patterns. Although the study is related to individuals, the message rings equally true for business. Careful control of spending is essential to long-term value building. Businesses vary considerably in their attitudes and discipline as it relates to control of overhead. Some businesses are rather cavalier about controlling things like light/electricity usage, control over low cost parts, efficiency in shipping methods, etc. Others are rather fanatical about maintaining absolute and stringent controls. For instance, one controller of a manufacturing plant was frustrated with the number of screws that were dropped and left to be swept away at the end of each business day. These were seemingly insignificant to the employees. In frustration, the controller scattered a box of nickels onto the factory floor -- by the end of the day none remained for the janitorial staff to sweep away. A subsequent memo was issued reminding everyone that screws cost 5 each. The rather obvious point was to draw a comparison between the nickels that everyone was eager to recover and the screws for which there was little concern. To build a successful business, a good manager will keep a keen eye on all overhead items, and control them with vigor. The variable overhead variances are macro indicators of success in accomplishing this goal.
outcome). Here our accounting objective will be to allocate the $70,000 actually spent between work in process and variance accounts. The temptation would be to book $72,000 into work in process and reflect a $2,000 offsetting favorable variance -- but that would be the wrong approach! Instead, the Work in Process account should reflect the standard fixed overhead cost for the output actually produced. We get to this calculated value by reconsidering the company's original assumptions about production. Assume that Blue Rail had planned on producing 4,000 rail systems during the month; remember that only 3,400 systems were actually produced -- output was disappointing, perhaps due to the inexperienced labor pool. This means that the planned fixed overhead was $18 per rail ($72,000/4,000 = $18). Because three labor hours are needed per rail, the fixed overhead allocation rate is $6 per direct labor hour ($18/3). Use this new information to consider the following illustration for fixed factory overhead (remember from the earlier discussion that the standard labor hours for the actual output were 10,200):
By reviewing this familiar looking illustration, you can see that $61,200 should be allocated to work in process. This reflects the standard cost allocation of fixed overhead that would be attributable to the production of 3,400 units (i.e., 10,200 hours should be used to produce 3,400 units). Notice that this differs from the
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budgeted amount of fixed overhead by $10,800, representing an unfavorable Fixed Overhead Volume Variance. In other words, since production did not rise to the anticipated level of 4,000 units, much of the fixed cost (that was in place to support 4,000 units of output) was "wasted" or "under-utilized." Thus, the measured volume variance is highly unfavorable. If more units had been produced than originally anticipated, the fixed overhead volume variance would be favorable (this would reflect total budgeted fixed overhead being spread over more units than originally anticipated). For Blue Rail, the volume variance is offset by the more easily understood favorable Fixed Overhead Spending Variance of $2,000; $70,000 was spent versus the budgeted $72,000. Together, the two variances combine to reveal a net $8,800 unfavorable Total Fixed Overhead Variance.
You will notice that the standard cost of $686,800 corresponds to the amounts assigned to work in process inventory via the various journal entries, while the total variances of $32,200 were charged/credited to specific variance accounts. By so doing, the full $719,000 actually spent is fully accounted for in the records of the Blue Rail.
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EXAMINING VARIANCES:
Not all variances need to be analyzed. One must consider the circumstances under which the variances resulted and the materiality of amounts involved. One should also understand that not all unfavorable variances are bad. For example, buying raw materials of superior quality (at higher than anticipated prices) may be offset by reduction in waste and spoilage. Likewise, favorable variances are not always good. Blue Rail's very favorable labor rate variance resulted from using inexperienced, less expensive labor. Was this the reason for the unfavorable outcomes in efficiency and volume? Perhaps! The challenge for a good manager is to take the variance information, examine the root causes, and take necessary corrective measures to fine tune business operations. In closing this discussion of standards and variances, be mindful that care should be taken in examining variances. If the original standards are not accurate and fair, the resulting variance signals will themselves can prove quite misleading.
approach may include target thresholds that should be met, the primary mantra is on improvement. This means that all participants are continually striving to beat pre-existing scores for each measure. We saw how responsibility accounting concepts caused performance reports to be prepared for different steps in the corporate ladder. This notion is equally applicable to the balanced scorecard approach. The overall corporate entity may have macro targets and measures. Similarly, sub-units will have their own unique goals. A scorecard approach can even be pushed down to the individual employee level. For instance, a retail store may require that tellers complete a certain number of transactions per hour. This "quota" in essence would represent a nonfinancial metric that can be scored for each employee.
Results of a customer satisfaction survey Product returns/warranty work rates The frequency that customers reorder (or do not reorder) Estimated market share New customers that are based on referrals of existing customers Frequency that customer bids lead to customer orders Customer complaint/compliment rates Price in comparison to competitors
Defect free units as a proportion of total production Frequency/size of product liability claims Time from order receipt to shipment Size of customer order backlogs
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o o o o
Employee turnover rate Employee morale survey results Employee accident rates/claims for workers' compensation Average experience level of employees
In reviewing this list of potential items for inclusion in a balanced scorecard performance appraisal, you have probably thought of some additional items for inclusion. The choice is up to management. The idea is to find those items that drive business success in a way that is consistent with the corporate philosophy. Perhaps Blue Rail has a goal of 100% customer satisfaction with respect to quality, but knows that its price will be 20% higher than competitors. Or, Blue Rail may have a goal of being the lowest cost provider and will tolerate some degree of customer discord. The metrics are intended to measure progress toward fulfillment of the corporate objectives, and the managerial accountant is apt to be heavily involved in gathering the necessary data for inclusion in the balanced scorecard performance reports. These reports are often graphical in nature to facilitate easy use and interpretation, with particular emphasis on timely identification of trends. Sometimes, the metrics are prominently posted in the work place; perhaps you have seen a sign at a construction site noting the number of consecutive accident free work days. By prominent display of such data, employees are constantly reminded of, and vigilant to meet, key performance goals.
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INTRODUCTION TO ORGANIZATION:
Bata had traditionally targeted the lower middle and middle class segments of the society and was now considering changes in its strategy to be able to survive in the market. The MD of Bat a was considering the efforts necessary to realign Bata Pakistans manufacturing, outsourcing, distribution and brand strategy in the light of increased local competition and Chinese imports.
The business that became the Bata Shoe Organization was established on August 24, 1895 in Zlin, Czechoslovakia by Tomas Bata, and included his brother Antonin and Sister Anna. Although this business was new, the Bata name had been part of a tradition of shoemaking for eight generations, spanning three hundred years. It was one of the first modern day shoe manufactures a team of snitchers and shoemakers creating footwear not just for the local town, but also for the distant retail merchants. This departure from the centuries old tradition of the one man cobblers workshop was a brand new concept, creating an entirely new industry.
The Bata enterprise revolutionized the treatment of employees and labor conditions. Tomas consistently maintained a human focus, creating opportunities fro development and advancement, and added compensation for employees based on achievement.
In late 1985 Antonin was drafted into the army for compulsory military service and lift family shoe business. Also that year, Anna left the company to marry, leaving a young Tomas to build the business on his own.
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By 1905 Tomas had taken the new enterprise to 2200 pairs of shoes per day, produced by 250 employees - utilizing resourceful imaginations, skilled hands and modern machinery to keep up with demand. Under this manufacturing system, productivity was greater then even before. Demand grew rapidly in the early 1900s despite material and manpower shortages, cartel and the outbreak of World War 1, sales continued to increase, reaching two million pairs per year by 1917. As the enterprise prospered, so did the communities where it operated, Tomas believed that a focus on people and public service was critical for business success. The enterprise built housing, schools and a hospital near the shoemaking plant in Zlin. It provided food and inexpensive rent during very difficult times; when there was no help to be found. Bata companies alter provided rail services, construction, insurance, publishing and tannery in Zlin.
Material Cost Variance can be derived as follows: MCV = (Standard Quantity x Standard Rate) - (Actual Quantity x Actual Rate)
1. Material Rate Variance or Material Price Variance is the variance in the rate or price of material actually spent and the material rate/price estimateMaterial Rate Variance can be derived as follows: MRV = Actual Quantity (Standard Price - Actual Price)
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2. Material Yield Variance: The difference between the actual output and the standard expected output is the Material Yield Variance.
There are two methods of calculating Material Yield Variance. They are as follows:
Input Method: MYV = (Standard Input - Actual Input) x Average Cost / unit
Output Method: MYV = (Actual Output - Standard Output) x Total Cost / unit
BEP in units = Fixed Cost / Contribution per unit BEP in cash = Fixed Cost / P.V. Ratio BEP in terms of capacity utilization = BEP in units / Total capacity x 100
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Retailing
Bata Shoe Organization companies have built successful retail store concepts to satisfy changing consumer tastes and needs. Each store features merchandise targeted to different lifestyles and people. The merchandise ranges from footwear to clothing and goods complementing shoe offerings. Sensitivity to and satisfaction of customer wants and needs has allowed the Bata Shoe Organization (BSO) to become a world leader in footwear.
Manufacturing
Tomas Bata's revolutionary business concept was to industrialize the shoemaking process of that day. That type of thinking has been the driving force behind the Bata Shoe Organization success. The Bata Shoe Organization has been an innovator in the manufacturing of shoes over the years. Bata personnel have made important advances in DVP (Direct Vulcanization Process), PVC, athletic footwear production and slush-molded footwear production.
Wholesaling
The Bata Shoe Organization [BSO] enjoys a unique position in the wholesale marketplace Global economies of scale enable BSO plants to offer quality products at local prices, with many operating at ISO standards.
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Bata Shoe Organization production facilities are world renowned for their commitment to quality and customers, and have attracted production contracts from many international footwear brands.
Bata Pakistan Ltd. is producing almost 13000 million pairs of shoes with in year but in year 2001 produces 13891 million pairs of shoes which shows the soundness of the organization and it strong footing in the Pakistan. Bata is still improving its business and know a days it become the most favorite footwear for people of Pakistan.
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EXAMPLE
The following data pertain to the first week of Bata Shoe in April.
Material Actual purchases Actual usage Standard usage Direct Labor Actual hours Standard hrs 310 hrs @ Rs. l2.30 hr 340 hrs @ l2 per hr 1500 @ Rs. 3.80 per unit 13 50 units 1020 units @ Rs 4 per unit
Solution MATERIAL PURCHASE PRICE VARIANCE Actual x (standard - actual units) 1500 x (4-3.80) 1500x0.2 = 300 favorable
Labor Rate Variance Actual labor cost. 310x12.30=3813 Standard labor hours 310x12 = 3729
Rs 93 favorable
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2010
1,798,712 200,705 84,877 6,588 26,771 4,603 11,613
2009
1,204,315 170,600 56,729 4,840 20,546 4,215 11,602
2,133,869
Add: opening goods in process 41,249
1,472,847
59,962
2,175,118
Less: closing goods in process 91,989
1,532,809
37,708
2,083,129
1,035,130 2,021,036
1,495,101
891,349 1,429,343
5,139,295
Less: closing stock of finished goods 1,523,853
3,815,793
1,062,278
3,615,442
2,753,515
Note: *Here BATA shoes financial statement shows the total cost of goods including (Direct Labor), (Direct Material) and (Factory Overhead) separately. Therefore we assume the (fuel, power, stores, repairs, insurance and depreciation) amount as Factory Overhead. Then the
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variance between 2010 and 2009 factory overhead is calculated below: Factory overhead 2009Factory overhead 2010FOH cost increased by 97,932 (less) 134,452 (36,520)
Sales
Net sales 2009Net sales 2010Increase in sales 4,733,331 (less) 6,118,643 (1,385,312)
Profit:
Profit after taxation 2009Profit after taxation 2010454,836 (less) 683,983 (229,147)
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After analyzing the following figures we came to result that hence the cost of FOH of BATA shoes is increased in 2010 but it belongs to others aspects as high production, increased sales and the company earns profit in 2010. When a company does heavy production it got heavy sales and heavy sales become a factor to earn heavy profits and when a company produces more than it is obvious to increase in cost.
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SWOT ANALYSIS
Strengths
1. Brand Image 2. Reasonable quality at low or reasonable price 3. Diversity with ranges in running, training, court, basketball, football and Outdoor 4. Footwear for the entire family 5. Financially Strong 6. Conveniently accessible outlets in various parts of the country 7. Targeting all income segments 8. Provide training for managers and employees 9. Nationwide retail network
Weaknesses
1. No continuity of leadership 2. In 2001, 5% decrease in net sales 3. No proper planning regarding Advertisement 4. No variety in Fashionable shoes
Opportunities
1. E-Commerce 2. Acquired, Partnership with small players 3. Entering new segments of Markets 4. Capturing Market where no other potential competitor exists 5. Innovative Products 6. New mediums for advertisements
Threats
1. Customer Dissatisfaction 2.Price wars with competitors
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CONCLUSION
As from the all discussion regarding Bata shoe as it is the manufacturing concern company and they bearing lots of cost and its may increase with time because it is not possible that actual and standard cost remain same. Variances create problem for the organization proper arrangement should be made.
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RECOMMENDATION
Financial Position of the Bata Pakistan limited is very impressive only in few of the department Bata is quite week. There is some of recommendations which help the management to overcome these deficiencies Bata Debt to Equity ratio is 3.51, which means almost 75 % are debts. Due to high debts ratio financial charges are increasing and consuming major portion of profit. Management has to reduce its debts to reduce the financial charges. Due to High debts ratio company will also find difficulties if they apply for the loan. Because none of the financial institution will like to invest money due to low equity ratio. Company's current ratio is 1.17:1 but the favorable and most acceptable is 2:1. So company should try to decrease its liabilities mainly the accrued expenses payable or to increase its current assets to be more positive.
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