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Cost Accounting: Traditions and Innovations

Jesse T. Barfield, Cecily A. Raiborn, Michael R. Kinney

Chapter 7

Special Production Issues: Lost Units and Accretion - all with Video Answers

Educators


Chapter Questions

Problem 1

Explain the meaning of an accepted quality level and discuss it in relation to a zero tolerance for defects or errors approach.

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05:00

Problem 2

Differentiate among shrinkage, spoilage, and defects.

Ameer Said
Ameer Said
Numerade Educator

Problem 3

What are some reasons a company would set a "tolerated" loss level? How might such a level be set?

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03:32

Problem 4

List five examples (similar to the blackened redfish illustration in the text) in which a unit would be considered (a) defective and (b) spoiled.

Muhammad Saleem
Muhammad Saleem
Numerade Educator

Problem 5

What is the difference between a normal and an abnormal lose?

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Problem 6

Why would abnormal losses be more likely to be preventable than some types of normal losses?

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02:36

Problem 7

How does a continuous loss differ from a discrete loss?

Harsh Gadhiya
Harsh Gadhiya
Numerade Educator

Problem 8

When does a discrete loss actually occur? When is it assumed to occur for accounting purposes? Why are these not necessarily at the same point?

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02:22

Problem 9

Why is the cost of an abnormal loss considered a period cost? How is its cost removed from Work in Process Inventory?

Ameer Said
Ameer Said
Numerade Educator
00:51

Problem 10

What is meant by the term metbod of neglect? When is this method used?

Emily Himsel
Emily Himsel
Numerade Educator
00:58

Problem 11

How does use of the method of neglect affect the cost of good production in a period?

Prashant Bana
Prashant Bana
Numerade Educator
00:30

Problem 12

In a job order costing system, spoilage may be incurred in general for all jobs or it may be related to a specific job. What differences do these circumstances make in the treatment of spoilage?

Ameer Said
Ameer Said
Numerade Educator

Problem 13

In a production process, what is accretion? How does it affect the cost of the units transferred in from a predecessor department?

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00:57

Problem 14

The Mixing Department of Leeward Company transferred 100,000 gallons of material to the Baking Department during July. The cost per gallon transferred out shown on Mixing's cost of production report was $$\$2.50$$. On Baking's cost of production report for the same period, the cost per gallon for material transferred in was $$\$ 2.00$$. Why might the cost have changed?

Erika Bustos
Erika Bustos
Numerade Educator
02:22

Problem 15

How are costs of reworking defective units treated if the defects are considered normal? Abnormal?

Ameer Said
Ameer Said
Numerade Educator

Problem 16

A company has an AQL for defects of 5 percent of units started during the period. Current period loss was 3 percent. Why should management attempt to measure the cost of this loss rather than simply include it as part of the cost of good production?

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Problem 17

How do statistical process control techniques contribute to the control of spoilage costs?

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Problem 18

Search the Internet for a company that has a zero tolerance for defects policy and report on the results of the company's efforts to reach its goals.

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Problem 19

Match the following lettered terms on the left with the appropriate numbered definition on the right.
1. Allowing the production of spoiled units to increase the cost of good production
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit
2. Decreases the transferred-in cost per unit
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit
3. Results from having defective production greater than the $\mathrm{AQL}$.
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit
4. A unit that is discarded on inspection
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit
5. A unit that can be reworked
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit
6. An expected decline in units in the production process
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit
7. Additional processing that results in net incremental revenue
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit
8. Maximum limit below which the frequency of defects in a process is accepted as normal
a. Abnormal loss
b. Acceptable quality level
c. Accretion
d. Defective unit
c. Economically reworked
f. Method of neglect
g. Normal loss
h. Spoiled unit

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Problem 20

Alfred Carlson, plant manager at WEBOXALL Company, is investigating spoilage created by a machine that prints packing boxes for TVs and other large, fragile items. At the beginning of each production run, 50 boxes are misprinted either because of miscoloration or misalignment. These boxes must be destroyed. The variable production cost per box is $$\$ 6,00$$. The machine averages 200 setups for production runs each year.
A regulator is available that will correct the problem. Alfred is trying to decide whether to purchase the regulator.
a. At what cost for the regulator would the benefit of acquisition not exceed the cost? What other factors should Alfred consider in addition to the purchase price of the regulator?
b. If each setup produces an average of 500 boxes, what is the increased cost per good box that is caused by the spoiled units?
c. WEBOXAL.L Company runs 12 batches per year for Springtime Corporation, which makes very specialized equipment in limited quantities. Thus, each batch contains only 20 boxes. If WEBOXAL.L. Company is passing its spoilage cost on to customers based on batch costs, might Springtime Corporation be willing to buy the regulator for WEBOXALL. Company if the regulator costs $$\$ 3,300$$ ? Justify your answer.
d. Why are the cost-per-box answers in parts (b) and (c) so different?

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Problem 21

Jacksonville Plastics uses a weighted average process costing system for its production process in which all material is added at the beginning of production. Company management has specified that the normal loss cannot exceed 7 percent of the units started in a period. All losses are caused by shrinkage. March processing information follows:
$$
\begin{array}{lr}
\text { Beginning inventory ( } 10 \% \text { complete-conversion) } & 8,000 \text { units } \\
\text { Started during March } & 60,000 \text { unts } \\
\text { Completed during March } & 53,000 \text { unts } \\
\text { Ending inventory ( } 60 \% \text { complete-conversion) } & 10,000 \text { units }
\end{array}
$$
a. How many total units are there to account for?
b. How many units should be treated as normal loss?
c. How many units should be treated as abnormal loss?
d. What are the equivalent units of production for direct material? For conversion?

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Problem 22

The Atlanta Division of Southeastern Paint produces environmental paints in processes in which spoilage takes place on a continual basis. Management considers normal spoilage to be 0.5 percent or less of gallons of material placed into production. The following operating statistics are available for June 2000 for the paint BMZ:
$$
\begin{array}{lr}
\text { Beginning inventory ( } 20 \% \text { complete as to material; } 30 \% \text { complete } & \\
\text { as to conversion) } & 8,000 \text { galions } \\
\text { Started during June } & 180,000 \text { gallons } \\
\text { Ending inventory ( } 60 \% \text { complete as to material; } 70 \% \text { complete } & \\
\text { as to conversion) } & 4,000 \text { gallons } \\
\text { Spoiled } & 1,400 \text { gallons }
\end{array}
$$
a. How many gallons were transferred out?
b. How much normal spoilage occurred?
c. How much abnormal spoilage occurred?
d. What are the FIFO equivalent units of production for materials? For conversion costs?
c. How are costs associated with the normal spoilage handled?
f. How are costs associated with the abnormal spoilage handled?

Donna Densmore
Donna Densmore
Numerade Educator
01:49

Problem 23

Arkansas Foods manufactures corn meal in a continuous, mass-production process. Com is added at the beginning of the process. Losses are few and occur only when foreign materials are found in the com meal. Inspection occurs at the 95 percent completion point as to conversion.
During May, a machine malfunctioned and dumped salt into 18,000 pounds of corn meal. This abnormal loss occurred when conversion was 70 percent complete on those pounds of product. The error was immediately noticed, and those pounds of com meal were pulled from the production process. An additional 1,000 pounds of meal were detected as unsuitable at the inspection point. These lost units were considered well within reasonable limits. May production data are shown below:
$$
\begin{array}{lr}
\text { Beginning work in process ( } 85 \% \text { complete) } & 50,000 \text { pounds } \\
\text { Started during the month } & 425,000 \text { pounds } \\
\text { Ending work in process ( } 25 \% \text { complete) } & 10,000 \text { pounds }
\end{array}
$$
a. Determine the number of equivalent units for direct material and for conversion assuming a FIFO cost flow.
b. If the costs per equivalent unit are $$\$ 2.50$$ and $$\$ 4.50$$ for direct material and conversion, respectively, what is the cost of ending inventory?
c. What is the cost of abnormal loss? How is this cost treated in May?

Jennifer Stoner
Jennifer Stoner
Numerade Educator

Problem 24

Candlesticks uses a FIFO process costing system to account for its candle production process. Wax occasionally forms imperfectly in molds and, thus, spoilage is viewed as continuous. The accepted quality level is good output of 92 percent of the pounds of wax placed in production. All wax is entered at the beginning of the process. March 2001 data follow:
$$
\begin{array}{lr}
\text { Beginning inventory (30\% complete as to conversion) } & 9,000 \text { pounds } \\
\text { Started during month } & 30,000 \text { pounds } \\
\text { Transferred } & 31,500 \text { pounds } \\
\text { ( } 315,000 \text { candles; } 10 \text { wax candles are obtained from a pound of wax) } & \\
\text { Ending inventory ( } 20 \% \text { complete as to conversion) } & 5,400 \text { pounds } \\
\text { Loss } & ? \text { pounds }
\end{array}
$$
The following costs are associated with March production:
$$
\begin{array}{lll}
\begin{array}{l}
\text { Beginning inventory: } \\
\text { Material }
\end{array} & \$ 3,600 & \\
\begin{array}{c}
\text { Conversion } \\
\text { Current period: }
\end{array} & \underline{2,700} & \$ 6,300 \\
\text { Material } & \$ 9,207 & \\
\begin{array}{c}
\text { Conversion } \\
\text { Total costs }
\end{array} & \underline{8,964} & \underline{18,171} \\
& & \underline{\$ 24,471}
\end{array}
$$
a. Prepare the production data segment of CandleSticks' cost of production report for March 2001.
b. Compute the cost per equivalent unit for each cost component.
c. Assign March costs to the appropriate units.

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Problem 25

CushionRide manufactures automobile springs. Its production equipment is fairly old, and one bad unit is typically produced for every 20 good units. The bad units cannot be reworked and must be discarded. Spoilage is determined at an end-of-process inspection point. CushionRide uses a weighted average process costing system and adds all material at the beginning of the process. The following data have been gathered from the accounting records for January 2001:
$$
\begin{array}{lr}
\text { Beginning inventory ( } 60 \% \text { complete as to conversion) } & 4,000 \text { units } \\
\text { Units started } & 20,000 \text { units } \\
\text { Ending inventory ( } 30 \% \text { complete as to conversion) } & 3,000 \text { units } \\
\text { Good units completed } & 20,000 \text { units }
\end{array}
$$
$$
\begin{array}{lccc}
& \text { Material } & \text { Conversion } & \text { Total } \\
\hline \text { Beginning inventory } & \$ 12,492 & \$ 9,927 & \$ 22,419 \\
\text { Current period } & \underline{112,548} & \underline{63,000} & \underline{175,548} \\
\text { Total costs } & \underline{\$ 125,040} & \underline{\$ 72,927} & \underline{\$ 197,967}
\end{array}
$$
a. Prepare an EUP schedule.
b. Determine the cost of the normal spoilage and allocate that cost to the appropriate inventory.

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42:33

Problem 26

The Potato Division of Global Foods Company processes potatoes, In the process, raw potatoes are sequentially cleaned, skinned, cooked, and canned. Spoilage amounting to less than 12 percent of the total pounds of potatoes that are introduced to the cleaning operation is considered normal (in this case, normal spoilage is to include the weight of the potato peels). Inspection occurs when the products are 50 percent complete. Information that follows pertains to operations in the Potato Division for January 2000 :
$$
\begin{array}{lr}
\text { Beginning WIP inventory ( } 30 \% \text { complete) } & 500,000 \text { pounds } \\
\text { Started } & 13,500,000 \text { pounds } \\
\text { Transferred } & 11,400,000 \text { pounds } \\
\text { Ending WIP inventory ( } 40 \% \text { complete) } & 750,000 \text { pounds }
\end{array}
$$
a. Compute the amount of spoilage in January. How much of the spoilage was normal?
b. Compute the equivalent units of production assuming the weighted average method is used.
c. Prepare a memo explaining why you might expect some (1) accretion in the canning operation and $(2)$ some shrinkage other than the weight of the peels in one or more of the operations.

Oluwadamilola Ameobi
Oluwadamilola Ameobi
Numerade Educator

Problem 27

Auto Luster Inc. manufactures two-gallon tubs of car polish for body shops. The company uses an actual cost, process costing system. All material is added at the beginning of production; labor and overhead are incurred evenly through the process. Defective units are identified through inspection at the end of the production process. The following information is available for August 2001 :
$$
\begin{array}{lr}
\text { Beginning inventory (30\% complete as to conversion) } & 750 \text { units } \\
\text { Started during month } & 17,250 \text { units } \\
\text { Completed during month } & 15,000 \text { units } \\
\text { Defective units ( } 100 \% \text { complete as to conversion) } & 1,800 \text { units } \\
\text { Ending inventory ( } 70 \% \text { complete as to conversion) } & 1,200 \text { units }
\end{array}
$$
a. Determine the equivalent units of production using the weighted average method.
b. Assume that the rework is normal. Determine the cost per good unit for direct material and conversion.
c. Assume that the rework is normal. How would the rework cost be handled in a normal (rather than actual) costing system?
d. Assume that the rework is abnormal. Determine the cost per good unit for direct material and conversion. How is the rework cost recorded for financial statement purposes?

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Problem 28

For each of the following types of production losses or poor service, indicate whether prevention (P) or appraisal (A) techniques would provide the most effective control mechanism. Explain why you made your choice.
a. Putting pages in upside down in a book.
b. Bolting the wrong parts together.
c. Shrinkage from cooking.
d. Breaking glasses when they are being boxed.
e. Paying an account payable twice.
f. Bringing the wrong meal to a restaurant customer.

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Problem 29

Department 1 of Super Patties cooks ground beef for hamburger patties. The patties are then transferred to Department 2 where they are placed on buns, boxed, and frozen. The accepted level of shrinkage in Department 1 is 10 percent of the pounds started. Super Patties uses a weighted average process costing system and has the following production and cost data for Department 1 for May 2001:
$$
\begin{array}{lr}
\text { Beginning inventory ( } 80 \% \text { complete as to conversion) } & 1,000 \text { pounds } \\
\text { Started } & 125,000 \text { pounds } \\
\text { Transferred to Department } 2 \text { ( } 550,000 \text { patties) } & 110,000 \text { pounds } \\
\text { Ending inventory ( } 30 \% \text { complete as to conversion) } & 3,000 \text { pounds } \\
\text { Beginning inventory cost of ground beet } & \$ 1,020 \\
\text { May cost of ground beef } & \$ 106,710 \\
\text { Beginning inventory conversion cost } & \$ 195 \\
\text { May conversion cost } & \$ 27,630
\end{array}
$$
a. What is the total shrinkage (in pounds)?
b. How much of the shrinkage is classified as normal? How is it treated for accounting purposes?
c. How much of the shrinkage is classified as abnormal? How is it treated for accounting purposes?
d. What is the total cost of the patties transferred to Department 22 Cost of ending inventory? Cost of abnormal spoilage?
e. How might Super Patties reduce its shrinkage loss? How, if at all, would your solution(s) affect costs?

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Problem 30

Angelique Inc. makes stuffed angels in a mass-production process. Cloth and stuffing are added at the beginning of the production process; the angels are packaged in sky-blue boxes at the end of production. Conversion costs for the highly automated process are incurred evenly throughout processing. The angels are inspected at the 95 percent completion point prior to being boxed. Defective units of more than 1 percent of the units started is considered abnormal.
The company uses a weighted average process costing system. June 2001 production and cost data for Angelique Inc. follow:
$$
\begin{array}{lr}
\text { Beginning inventory (40\% complete as to conversion) } & 5,000 \\
\text { Started } & 70,000 \\
\text { Ending inventory ( } 70 \% \text { complete as to conversion) } & 6,000 \\
\text { Total defective units } & 400 \\
\text { Beginning inventory cloth and stuffing cost } & \$ 21,900 \\
\text { Beginning inventory conversion cost } & \$ 7,680 \\
\text { June cloth and stuffing cost } & \$ 315,600 \\
\text { June box cost } & \$ 75,460 \\
\text { June conversion cost } & \$ 270,404
\end{array}
$$
a. How many units were completed in June?
b. How many of the defective units are considered a normal loss? An abnomal loss?
c. What is the per-unit cost of the completed units? What would the per-unit cost of the completed units have been if the 400 units had been good units at their same stages of completion at the end of the period?
d. What is the total cost of ending inventory?

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Problem 31

Brendan Tools manufactures one of its products in a two-department process. A separate Work in Process account is maintained for each department, and Brendan Tools uses a weighted average process costing system. The first department is Molding; the second is Grinding. At the end of production in Grinding, a quality inspection is made and then packaging is added. Overhead is applied in the Grinding Department on a machine-hour basis. Production and cost data for the Grinding Department for August 2000 follow:
$$
\begin{aligned}
&\text { Production Data }\\
&\begin{array}{lr}
\hline \text { Beginning imventory (complete: labor, } 30 \% \text {; overhead, 40\%) } & 2,000 \text { units } \\
\text { Transferred-in from Molding } & 49,800 \text { units } \\
\text { Normal spolage (discrete-found at the end of processing during quality control) } & 650 \text { units } \\
\text { Abnormal spoilage (found at end of processing during quality control) } & 350 \text { units } \\
\text { Ending inventory (complete: labor, } 40 \% ; \text {; overhead, } 65 \% \text { ) } & 1,800 \text { units } \\
\text { Transferred to finished goods } & \text { ? units }
\end{array}
\end{aligned}
$$
$$
\begin{array}{lrr}
\text { Cost Data } \\
\hline \text { Beginning inventory: } & & \\
\text { Transterred-in } & \$ 6,050 & \\
\text { Maferial (label and package) } & 0 & \\
\text { Direct labor } & 325 & \\
\text { Overhead } & 750 & \$ 7,125 \\
\text { Current period: } & \$ 149,350 & \\
\text { Transferred-in } & 11,760 & \\
\text { Material (label and package) } & 23,767 & \\
\text { Direct labor } & \underline{50,932} & \underline{235,809} \\
\text { Overhead } & & \underline{\$ 242,934}
\end{array}
$$
a. Prepare a cost of production report for the Grinding Department for August.
b. Prepare the journal entry to dispose of the cost of abnormal spoilage.

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Problem 32

Big Stone Furniture produces breakfast tables in a two-department process: Cutting/Assembly and Lamination. Varnish is added in the Lamination Department when the goods are 60 percent complete as to overhead. Spoiled units are found on inspection at the end of production. Spoilage is considered discrete.
$$
\begin{aligned}
&\text { PRODUCTION DATA FOR APRIL } 2000\\
&\begin{array}{lr}
\hline \text { Beginning inventory (80\% complete as to labor, 70\% complete as to overhead) } & 2,000 \text { unts } \\
\text { Transferred in during month } & 14,900 \text { units } \\
\text { Ending inventory (40\% complete as to labor, 20\% complete as to overhead) } & 3,000 \text { units } \\
\text { Normal spoilage (found at final quality inspection) } & 200 \text { units } \\
\text { Abnormal spolage (found at } 30 \% \text { completion as to labor and } 15 \% \text { as to } & 400 \text { units } \\
\quad \text { overhead; the sanding machine was misaligned and scarred the tables) } &
\end{array}
\end{aligned}
$$
$$
\begin{aligned}
&\text { COST DATA FOR APRIL } 2000\\
&\begin{array}{lrr}
\hline \text { Beginning Work in Process Inventory: } & & \\
\text { Prior department costs } & \$ 15,020 & \\
\text { Varnish } & 1,900 & \\
\text { Direct labor } & 4,388 & \\
\text { Overhead } & 11,044 & \$ 32,352 \\
& & \\
\text { Prior department costs } & \$ 137,080 & \\
\text { Vamish } & 14,030 & \\
\text { Direct labor } & 46,000 & \\
\text { Overhead } & 113,564 & \underline{310,674} \\
\quad \text { Total costs to account for } & & \$ 343,026
\end{array}
\end{aligned}
$$
Determine the proper disposition of the April costs for the Lamination Department using the weighted average method; include joumal entries.

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Problem 33

Use the Big Stone Furniture information from Problem 32. Determine the proper disposition of the April costs of the Lamination Department using the FIFO method; include journal entries.

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Problem 34

Reagan Company produces hinges. Completed hinges are inspected at the end of production. Any spoilage in excess of 2 percent of the completed units is considered abnormal. Material is added at the start of production. Labor and overhead are incurred evenly throughout production.
Reagan's May 2001 production and cost data follow:
$$
\begin{array}{lr}
\text { Beginning inventory ( } 50 \% \text { complete) } & 5,600 \\
\text { Units started } & 74,400 \\
\text { Good units completed } & 70,000 \\
\text { Ending inventory ( } 1 / 3 \text { complete) } & 7,500
\end{array}
$$
$$
\begin{array}{|c|c|c|c|}
\hline & \text { Material } & \text { Conversion } & \text { Total } \\
\hline \text { Beginning inventory } & \$ 6,400 & \text { \$ } 1,232 & \text { \$ } 7,632 \\
\hline \text { Current period } & 74,400 & 31,768 & 106,168 \\
\hline \text { Total } & \frac{14,700}{\$ 80,800} & \$ 33,000 & \$ 113,800 \\
\hline
\end{array}
$$
Galculate the equivalent units schedule, prepare a FIFO cost of production report, and assign all costs.

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01:28

Problem 35

Use the Reagan Company data as given in Problem 34. Prepare a May 2001 cost of production report using the weighted average method.

Adriano Chikande
Adriano Chikande
Numerade Educator

Problem 36

Data below summarize operations for GreenerGrass Company for March 2001. The company makes five-gallon containers of weed killer/ fertilizer. All material is added at the beginning of the process.
$$
\begin{array}{|c|c|c|c|}
\hline\text { Cost} & \text { Material } & \text { Conversion } & \text { Total } \\
\hline \text { Beginning inventory } & \text { \$ } 30,000 & \$ 3,600 & 33,600 \\
\hline \text { Current period } & 885,120 & 335.088 & 1,220,208 \\
\hline \text { Total costs } & \$ 915,120 & \$ 338,688 & \overline{\$ 1,253,808} \\
\hline
\end{array}
$$
$$
\begin{aligned}
&\text { UNITS }\\
&\begin{array}{lr}
\text { Beginning inventory ( } 30 \% \text { complete-conversion) } & 6,000 \text { units } \\
\text { Started } & 180,000 \text { units } \\
\text { Completed } & 152,000 \text { units } \\
\text { Ending inventory ( } 70 \% \text { complete-conversion) } & 20,000 \text { units } \\
\text { Normal spoilage } & 4,800 \text { units }
\end{array}
\end{aligned}
$$
Spoilage is detected at inspection when the units are 60 percent complete.
a. Prepare an EUP schedule using the weighted average method.
b. Determine the cost of goods transferred out, ending inventory, and abnormal spoilage.

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Problem 37

Patio Products employs a weighted average process costing system for its products, One product passes through three departments (Molding, Assembly, and Finishing) during production. The following activity took place in the Finishing Department during May 2001:
$$
\begin{array}{lr}
\text { Units in beginning inventory } & 4,200 \\
\text { Units transferred in from Assembly } & 42,000 \\
\text { Units spoiled } & 2,100 \\
\text { Good units transferred out } & 33,600
\end{array}
$$
The equivalent units and the costs per equivalent unit of production for each cost factor are as follows:
$$
\begin{array}{lr}
\text { Cost of prior departments } & \$ 5.00 \\
\text { Raw material } & 1.00 \\
\text { Conversion } & 3.00 \\
\hline \text { Total cost per EUP } & \$ 9.00
\end{array}
$$
Raw material is added at the beginning of processing in Finishing without changing the number of units being processed. Work in Process Inventory was 70 percent complete as to conversion on May 1 and 40 percent complete as to conversion on May 31. All spoilage was discovered at final inspection. Of the total units spoiled, 1,680 were within normal limits.
a. Calculate the equivalent units of production.
b. Determine the cost of units transferred out of Finishing.
c. Determine the cost of ending Work in Process Inventory.
d. The portion of the total transferred-in cost associated with beginning Work in Process Inventory amounted to $$\$ 18,900$$. What is the current period cost that was transferred in from Assembly to Finishing?
e. Determine the cost associated with abnormal spoilage for the month. How would this amount be accounted for?

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Problem 38

Harper Company produces brooms. Department 1 winds and cuts straw into broom heads and transfers these to Department 2 where the broom head is bound and attached to a handle. Straw is added at the beginning of the first process, and the handle is added at the end of the second process.
Normal losses in Department 1 should not exceed 5 percent of the units started; losses are determined at an inspection point at the end of the production process. The AQL in Department 2 is 10 percent of the broom heads transferred in; losses are found at an inspection point located 70 percent of the way through the production process.
The following production and cost data are available for October 2001.
$$
\begin{array}{lrr}
\hline & \text { Dept. 1 } & \text { Dept. 2 } \\
\hline \text { Beginning inventory } & 6,000 & 3,000 \\
\text { Started or transferred in } & 150,000 & ? \\
\text { Ending inventory } & 18,000 & 15,000 \\
\text { Spoiled units } & 9,000 & 6,000 \\
\text { Transferred out } & ? & 111,000
\end{array}
$$
$$
\begin{aligned}
&\text { COST RECORD }\\
&\begin{array}{lrr}
\hline \text { Beginning inventory: } & & \\
\quad \text { Preceding department } & \mathrm{n} / \mathrm{a} & \$ 6,690 \\
\text { Material } & \$ 3,000 & 0 \\
\quad \text { Conversion } & 2,334 & 504 \\
\text { Current period: } & & \\
\quad \text { Preceding department } & \mathrm{N} / \mathrm{a} & 230,910^* \\
\text { Material } & 36,000 & 740 \\
\text { Conversion } & 208,962 & 52,920
\end{array}
\end{aligned}
$$
The beginning and ending inventory units in Department 1 are, respectively, 10 percent and 60 percent complete as to conversion. In Department 2 , the beginning and ending units are, respectively, 40 percent and 80 percent complete as to conversion.
Using the weighted average method, create a cost of production report for each department for October 2001.

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Problem 39

Use the information for Harper Company from Problem 38 to prepare a FIFO cost of production report for each department for October 2001.

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Problem 40

Andaman Company mines salt in southem Florida, Approximately 30 percent of the mined salt is processed into table salt. Andaman Company uses a process costing system for the table salt operation. Processing takes place in two departments. Department 1 uses FIFO costing, and Department 2 uses weighted average. The cost of the processed salt transferred from Department 1 to Department 2 is averaged over all the units transferred.
Salt is introduced into the process in Department 1. Spoilage occurs continuously through the department and normal spoilage should not exceed 10 percent of the units started; a unit is 50 pounds of salt.
Department 2 packages the salt at the 75 percent completion point; this material does not increase the number of units processed. A quality control inspection takes place when the goods are 80 percent complete. Spoilage should not exceed 5 percent of the units transferred in from Department 1.
The following production and cost data are applicable to Andaman Company's table salt operations for July 2001:
$$
\begin{aligned}
&\text { DEPARTMENT } 1 \text { PRODUCTION DATA }\\
&\begin{array}{lr}
\hline \text { Beginning inventory (65\% complete) } & 5,000 \\
\text { Units started } & 125,000 \\
\text { Units completed } & 110,000 \\
\text { Units in ending inventory (40\% complete) } & 14,000
\end{array}
\end{aligned}
$$
$$
\begin{array}{lrr}
\hline \text { Beginning inventory: } & \\
\quad \text { Material} & \$ 7,750 & \\
\text { Conversion } & 11,500 & \$ 19,250 \\
\text { Current period: } &\$190,400 & \\
\quad \text { Material } &393,225 & 583,625 \\
\text { Conversion } & & \\
\quad \text { Total costs to account for } & &\$602,875
\end{array}
$$
$$
\begin{aligned}
&\text { DEPARTMENT } 2 \text { PRODUCTION DATA }\\
&\begin{array}{lr}
\hline \text { Beginning inventory ( } 90 \% \text { complete) } & 40,000 \\
\text { Units transferred in } & 110,000 \\
\text { Units completed } & 120,000 \\
\text { Units in ending inventory (20\% complete) } & 22,500
\end{array}
\end{aligned}
$$
$$
\begin{array}{lrr}
\hline \text { Beginning inventory: } & \\
\quad \text { Transferred-in } & \$ 204,000 & \\
\text { Material } & 120,000 & \\
\text { Conversion } & 21,600 & \$ 345,600 \\
\text { Current period: } & \$ 568,500^* & \\
\quad \text { Transferred-in } & 268,875 & \\
\quad \text { Material } & \underline{55,395} & \underline{892,770} \\
\text { Conversion } & & \\
\quad \text { Total costs to account for } & &\$1,238,370
\end{array}
$$
a. Compute the equivalent units of production in each department.
b. Determine the cost per equivalent unit in each department and compute the cost transferred out, cost in ending inventory, and cost of spoilage (if necessary).

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Problem 41

Hoffus Corporation produces plastic pipe and accounts for its production process using weighted average process costing. Material is added at the beginning of production. The company applies overhead to products using machine hours. Hoffus Corporation used the following information in setting its predetermined overhead rate for 2000 :
$$
\begin{array}{lr}
\text { Expected overhead other than rework } & \$ 425,000 \\
\text { Expected rework costs } & 37,500 \\
\hline \text { Total expected overhead } & \$ 462,500 \\
\hline \text {Expected machine hours for 2000}& 50,000
\end{array}
$$
During 2000, the following production and cost data were accumulated:
$$
\begin{array}{lr}
\text { Total good production completed } & 2,000,000 \text { feet of pipe } \\
\text { Total defects } & 40,000 \text { feet of pipe } \\
\text { Ending inventory (35\% complete) } & 75,000 \text { feet of pipe }
\end{array}
$$
$$
\begin{array}{ll}
\text { Total (beginning inventory and current period) cost of direct material } & \$ 3,750,000 \\
\text { Total (beginning inventory and current period) cost of conversion } & \$ 5,650,000 \\
\text { Cost of reworking defects } & \$ 37,750
\end{array}
$$
Hoffus Corporation sells pipe for $$\$ 3.50$$ per foot.
a. Determine the overhead application rate for 2000 .
b. Determine the cost per pipe-foot for production in 2000 .
c. Assume that the rework is normal and those units can be sold for the regular selling price. How will Hoffus Corporation account for the $$\$ 37,750$$ of rework cost?
d. Assume that the rework is normal, but the reworked pipe is irregular and can only be sold for $$\$ 2.50$$ per foot. Prepare the joumal entry to establish the inventory account for the reworked pipe. What is the total cost per unit for the good output completed?
e. Assume that 20 percent of the rework is abnormal and that all reworked output is irregular and can be sold for only $$\$ 2.50$$ per foot. Prepare the journal entry to establish the inventory account for the reworked pipe. What is the total cost per foot for the good output completed during 2000 ?

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05:24

Problem 42

Argonne Rigging manufactures pulley systems to customer specifications and uses a job order system. A recent order from Michaels Company was for 10,000 pulleys, and the job was assigned number BA468. The job cost sheet for $\equiv$ BA468 revealed the following:
$$
\begin{aligned}
&\text { WIP-JOB \#BA468 }\\
&\begin{array}{lr|r}
\hline \text { Direct material } & \$ 20,400 & \\
\text { Direct labor } & 24,600 & \\
\text { Overhead } & 18,400 & \\
\hline \text { Total } & \$ 63,400 &
\end{array}
\end{aligned}
$$
Final inspection of the 10,000 pulleys revealed that 230 of the pulleys were defective. In correcting the defects, an additional $$\$ 950$$ of cost was incurred ( $$\$ 250$$ for direct material and $$\$ 700$$ for direct labor). After the defects were cured, the pulleys were included with the other good units and shipped to the customer.
a. Assuming the rework costs are normal but specific to this job, show the journal entry to record incurrence of the rework costs.
b. Assuming the company has a predetermined overhead rate that includes normal rework costs, show the journal entry to record incurrence of the rework costs.
c. Assuming the rework costs are abnormal, show the journal entry to record incurrence of the rework costs.

Shamshad Waris
Shamshad Waris
Numerade Educator

Problem 43

Grand Monde Company manufactures various lines of bicycles. Because of the high volume of each type of product, the company employs a process cost system using the weighted average method to determine unit costs. Bicycle parts are manufactured in the Molding Department and transferred to the Assembly Department where they are partially assembled. After assembly, the bicycle is sent to the Packing Department.
Cost-per-unit data for the 20 -inch dirt bike has been completed through the Molding Department. Annual cost and production figures for the Assembly Department are presented at the top of the next page.
$$
\begin{aligned}
&\text { PRODUCTION DATA }\\
&\begin{array}{lr}
\text { Beginning inventory ( } 100 \% \text { complete as to transferred-in; } 100 \% \text { complete } \\
\text { as to assembly material; } 80 \% \text { complete as to conversion) } & 3,000 \text { units } \\
\text { Transferred in during the year ( } 100 \% \text { complete as to transferred-in) } & 45,000 \text { units } \\
\text { Transferred to Packing } & 40,000 \text { units } \\
\text { Ending inventory ( } 100 \% \text { complete as to transferred-in; } 50 \% \text { complete } & \\
\quad \text { as to assembly material; } 20 \% \text { complete as to conversion) } & 4,000 \text { units }
\end{array}
\end{aligned}
$$
$$
\begin{aligned}
&\text { COST DATA }\\
&\begin{array}{lccc}
\hline & \text { Transferred-In } & \text { Diroct Material } & \text { Conversion } \\
\hline \begin{array}{l}
\text { Beginning inventory } \\
\text { Current period }
\end{array} & \$ \$ 2,200 & \$ 6,660 & \$ 11,930 \\
\text { Totals } & \underline{1,237,800} & \underline{96,840} & \underline{236,590} \\
\hline 1,320,000 & \underline{\$ 103,500} & \underline{\$ 248,520}
\end{array}
\end{aligned}
$$
Damaged bicycles are identified on inspection when the assembly process is 70 percent complete; all assembly material has been added at this point of the process. The normal rejection rate for damaged bicycles is 5 percent of the bicycles reaching the inspection point. Any damaged bicycles above the 5 percent quota are considered to be abnormal. All damaged bikes are removed from the production process and destroyed.
a. Compute the number of damaged bikes that are considered to be
1. a normal quantity of damaged bikes.
2. an abnormal quantity of damaged bikes.
b. Compute the weighted average equivalent units of production for the year for
1. bicycles transferred in from the Molding Department.
2. bicycles produced with regard to assembly material.
3. bicycles produced with regard to assembly conversion.
c. Compute the cost per equivalent unit for the fully assembled dirt bike.
d. Compute the amount of the total production cost of $$\$ 1,672,020$$ that will be associated with the following items:
1. Normal damaged units
2. Abnormal damaged units
3. Good units completed in the Assembly Department
4. Ending Work in Process Inventory in the Assembly Department
e. Describe how the applicable dollar amounts for the following items would be presented in the financial statements:
1. Normal damaged units
2. Abnormal damaged units
3. Completed units transferred to the Packing Department
4. Ending Work in Process Inventory in the Assembly Department
f. Determine the cost to Grand Monde Company of normal spoilage. Discuss some potential reasons for spoilage to occur in this company. Which of these reasons would you consider important enough to correct and why? How might you attempt to correct these problems?

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Problem 44

Audiospectrum produces complex printed circuits for stereo amplifiers. The circuits are sold primarily to major component manufacturers, and any production overruns are sold to small manufacturers at a substantial discount. The small manufacturer segment appears to be very profitable because the basic operating budget assigns all fixed expenses to production for the major manufacturers, the only predictable market.
A common product defect that occurs in production is a "drift," caused by failure to maintain precise heat levels during the production process. Rejects from the 100 percent testing program can be reworked to acceptable levels if the defect is drift. However, in a recent analysis of customer complaints, Andrew Hill, the cost accountant, and the quality control engineer have ascertained that normal rework does not bring the circuits up to standard. Sampling shows that about one-half of the reworked circuits fail after extended, high-volume amplifier operation. The incidence of failure in the reworked circuits is projected to be about 10 percent over one to five years of operation.
Unfortunately, there is no way to determine which reworked circuits will fail because testing does not detect this problem. The rework process could be changed to correct the problem, but the cost-benefit analysis for the suggested change in the rework process indicates that it is not practicable. Audiospectrum's marketing analyst feels that this problem will have a significant impact on the company's reputation and customer satisfaction if it is not corrected. Consequently, the board of directors would interpret this problem as having serious negative implications for the company's profitability.
Hill has included the circuit failure and rework problem in his report for the upcoming quarterly meeting of the board of directors. Due to the potential adverse economic impact, Hill has followed a long-standing practice of highlighting this information.
After reviewing the reports to be presented, the plant manager and her staff were upset and indicated to the controller that he should control his people better. "We can't upset the board with this kind of material. Tell Hill to tone that down. Maybe we can get it by this meeting and have some time to work on it. People who buy those cheap systems and play them that loud shouldn't expect them to last forever."
The controller called Hill into his office and said, "Andrew, you'll have to bury this one. The probable failure of reworks can be referred to briefly in the oral presentation, but it should not be mentioned or highlighted in the advance material mailed to the board."
Hill feels strongly that the board will be misinformed on a potentially serious loss of income if he follows the controller's orders. Hill discussed the problem with the quality control engineer, who simply remarked, "That's your problem, Andrew."
a. Discuss the ethical considerations that Andrew Hill should recognize in deciding how to proceed in this matter.
b. Explain what ethical responsibilities should be accepted in this situation by
1. The controller.
2. The quality control engineer.
3. The plant manager and her staff.
c. What should Andrew Hill do in this situation? Explain your answer.

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Problem 45

Every job has certain requirements, and quality is defined by meeting those requirements. In some cases, however, people make decisions to override requirements. In a team of three or four, choose four requirements for your class (or for a job held by one of you). Prepare a memo that would explain to your teacher (or your boss) the following:
a. The requirements you have chosen and why you think the teacher (boss) made those requirements.
b. The conditions under which your team would decide to override the requirements.
c. Why you believe that overriding the requirements would be appropriate in the conditions you have specified.
d. The potential for problems that may arise by overriding the requirements.

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Problem 46

Use library, Internet, or personal resources to find three companies that instituted workforce education programs and, thereby, reduced the number of lost units. Prepare a five- to seven-minute oral presentation about your companies' programs and their benefits.

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Problem 47

All world-class models (TQM, JIT, ABM, and theory of constraints) advocate improving throughput as a way to improve quality and minimize defects. Prepare a report for the board of directors of a company for which you are the newly appointed controller explaining why increasing throughput is linked to quality improvements and reduction of defects.

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Problem 48

In accounting for spoilage, consideration should be given to how well the approach chosen to measure spoilage supports management's efforts to improve quality. Prepare a memo explaining how selecting a method to measure and account for spoilage can either assist or hinder management's efforts to improve quality.

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05:36

Problem 49

The following is an excerpt from the Web site of Zero Defects, an electronics manufacturing service provider:
At Zero Defects, we bave never believed that perfoction is too mucb for our clients to expect. For over 15 years, the uorld's leading electronics companies bave relied on us to provide legendary service and manufacture faultless products. When we say faultess, we mean mucb more than you migbt tbink. To us perfection means:
• Delivering $100 \%$ usable product on time, every time.
• Providing sentice tbat meets and exceeds every expectation.
• Manufacturing eacb component in the most cost-effective way possible.
• Meeting your exact specifications and customizing any part of our production line to do so.
• Keeping costs at a bare minimum tbrougb tigbt internal controls and volume buying potwer.
• Providing and standing by detailed quotations and schedules.
• Pretenting environmental damage tbrougb safe manufacturing and recycling programs.
Write a report briefly discussing this excerpt. Compare and contrast the approach explained in the excerpt with the traditional notion of only undertaking an action for which there is an expected net benefit using cost-benefit analysis.

Lottie Adams
Lottie Adams
Numerade Educator

Problem 50

Find three companies on the Internet (other than GE, the company featured in this chapter) that are using Six Sigma. Briefly discuss the results they have experienced from using it.

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