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James A. Hall
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Objectives for Chapter 7
y Elements and procedures of a traditional production
process
y Data flows and procedures in a traditional cost accounting
system
y Accounting controls in a traditional environment
y Principles, operating features, and technologies of lean
manufacturing
y Shortcomings of traditional accounting methods in the
world‐class environment
y Key features of activity based costing and value stream
accounting
y Information systems of lean manufacturing and world‐
class companies
The Conversion Cycle
y Transforms input resources, raw materials,
labor, and overhead into finished products
or services for sale
y Consists of two subsystems:
y Physical activities – the production system
y Information activities – the cost accounting
system
Conversion Cycle in Relation to Other Cycles
Marketing
System
Sales
Forecast
Purchase Requisitions
Revenue Cycle Sales Orders
Conversion Expenditure
Cycle Cycle
Labor Usage
Work
Finished
In
Goods
Process
General Ledger
and Financial
Reporting System
Production System
y Involves the planning, scheduling, and control of
the physical product through the manufacturing
process
y determining raw materials requirements
y authorizing the release of raw materials into
production
y authorizing work to be conducted in the
production process
y directing the movement of work through the
various stages of production
Production Methods
y Continuous Processing creates a homogeneous
product through a continuous series of standard
procedures.
y Batch Processing produces discrete groups
(batches) of products.
y Make‐to‐Order Processing involves the fabrication
of discrete products in accordance with customer
specifications.
Overview: Traditional Batch
Production Model…
y consists of four basic processes:
y plan and control production
y perform production operations
y maintain inventory control
y perform cost accounting
Batch Production System
y Production Planning and Control
y Materials and operations requirements
y Production scheduling
y Materials and Operations Requirements
y Materials requirement – the difference between what is
needed and what is available in inventory
y Operations requirements – the assembly and/or
manufacturing activities to be applied to the product
Batch Production System
y Production Scheduling
y Coordinates the production of multiple batches
y Influenced by time constraints, batch size, and
other specifications
y Work Centers and Storekeeping
y Production operations begin when work centers
obtain raw materials from storekeeping.
y It ends with the completed product being sent to
the finished goods (FG) warehouse .
Batch Production System
y Inventory Control
y Objective: minimize total inventory cost while
ensuring that adequate inventories exist of
production demand
y Provides production planning and control with
status of finished goods and raw materials inventory
y Continually updates the raw material inventory
during production process
y Upon completion of production, updates finished
goods inventory
EOQ Inventory Model
y Very simple too use, but assumptions are not always
valid
y demand is known and constant
y ordering lead time is known and constant
y total cost per year of placing orders decreases as the
order quantities increase
y carrying costs of inventory increases as quantity of
orders increases
y no quantity discounts
EOQ Inventory Model
INVENTORY LEVEL
EOQ
Reorder
Point
Engineering Specifications
BOM and Route Sheets Operations Requirements
Production Scheduling
Work Orders
Move Tickets
Materials Requisitions
Open Work Orders
Work Centers
Job Tickets Cost Accounting
Time Cards Payroll
Completed Move Tickets Prod. Plan. and Control
Upon Completion of the Production Process…
Finished Product Finished Goods Warehouse
and Closed Work Order
Inventory Control
Status Report of Raw Materials
and Finished Goods Prod. Plan. and Control
COST ACCOUNTANTS
Update WIP accounts
STANDARDS DL
DM
Mfg. OH.
Compute Variances
Cost Accounting System
y Receipt of last move ticket signals
completion of the production process
y clerk removes the cost sheet from WIP
file
y prepares a journal voucher to transfer
balance to a finished goods inventory
account and forwards to the General
Ledger department
Summary of Internal Controls
Internal Controls
y Transaction authorizations
y work orders – reflect a legitimate need
based on sales forecast and the finished
goods on hand
y move tickets – signatures from each work
station authorize the movement of the batch
through the work centers
y materials requisitions – authorize the
warehouse to release materials to the work
centers
Internal Controls
y Segregation of duties
y production planning and control
department is separate from the work
centers
y inventory control is separate from materials
storeroom and finished goods warehouse
y cost accounting function accounts for WIP
and should be separate from the work
centers in the production process
Internal Controls
y Supervision
y work center supervisors oversee the usage of
raw materials to ensure that all released
materials are used in production and waste
is minimized
y employee time cards and job tickets are
checked for accuracy
Internal Controls
y Access control
y direct access to assets
y controlled access to storerooms, production
work centers, and finished goods warehouses
y quantities in excess of standard amounts
require approval
y indirect access to assets
y controlled use of materials requisitions, excess
materials requisitions, and employee time
cards
Internal Controls
y Accounting records
y pre‐numbered documents
y work orders
y cost sheets
y move tickets
y job tickets
y material requisitions
y WIP and finished goods files
Internal Controls
y Independent verification
y cost accounting reconciles material usage (material
requisitions) and labor usage (job tickets) with
standards
y variances are investigated
y GL dept. verifies movement from WIP to FG by
reconciling journal vouchers from cost accounting and
inventory subsidiary ledgers from inventory control
y internal and external auditors periodically verify the
raw materials and FGs inventories through a physical
count
World‐Class Companies…
y continuously pursue improvements in all
aspects of their operations, including
manufacturing procedures
y are highly customer oriented
y have undergone fundamental changes from
the traditional production model
y often adopt a lean manufacturing model
Principles of Lean Manufacturing
y Pull Processing – products are pulled from the
consumer end (demand), not pushed from the
production end (supply)
y Perfect Quality –pull processing requires zero defects
in raw material, WIP, and FG inventories
y Waste Minimization – activities that do not add value
or maximize the use of scarce resources are
eliminated
y Inventory Reduction – hallmark of lean manufacturing
y Inventories cost money
y Inventories can mask production problems
y Inventories can precipitate overproduction
Principles of Lean Manufacturing
y Production Flexibility – reduce setup time to a
minimum, allowing for a greater diversity of products,
without sacrificing efficiency
y Established Supplier Relations – late deliveries,
defective raw materials, or incorrect orders will shut
down production since there are no inventory
reserves
y Team Attitude – each employee must be vigilant of
problems that threaten the continuous flow of the
production line
Lean Manufacturing Model
y Achieve production flexibility by means of:
y Changes in the physical organization of
production facilities
y Employment of automated technologies
y CIM, AS/RS, robotics, CAD, and CAM
y Use of alternative accounting models
y ABC and value stream accounting
y Use of advanced information systems
y MRP, MRPII, ERP, and EDI
Physical Reorganization of the
Production Facilities
y Inefficiencies in traditional plant layouts increase
handling costs, conversion time, and excess
inventories.
y Employees tend to feel ownership over their stations,
contrary to the team concept.
y Reorganization is based on flows through cells which
shorten the physical distance between activities.
y This reduces setup and processing time, handling costs,
and inventories.
Progression of Automation in
the Manufacturing Process