Chips Manufacturing Cost Guide
Chips Manufacturing Cost Guide
Written By:
Master of Commerce
Submitted To:
Master of Commerce
Master
In
Commerce
Submitted By
Mr.
Mubashir
Hassan
Khan
Table of Contents
Topic Page No
Acknowledgment..................................................................……….07
Executive Summary………………………………………………...08
Cost Accounting ……………………………………….....................08
Cost Classifications………………………………………………….08
4
Characteristics Of Good Cost System……………………………...11
Machinery Requirements…………………………………………...16
Fixed Assets Requirements…………………………………………17
Raw Material Requirements………………………………………..18
Land & Building Requirements…………………………………....19
Human Resource Requirements……………………………………20
Key Assumptions…………………………………………………….21
Operating Assumptions……………………………………………..22
Revenue Assumptions……………………………………………….22
Expense Assumptions……………………………………………….23
Turnover Assumptions……………………………………………...23
References…………………………………………………………....26
5
6
Acknowledgement
7
Executive Summary:
Cost Classifications
Costs are classified into fixed costs, variable costs or mixed costs (based on
behavior); product costs or period costs (for external reporting); direct costs or
indirect costs (based on traceability); and sunk costs, opportunity costs or
incremental costs (for decision-making).
8
Product Costs vs Period Costs
9
Product costs (also called inventoriable costs) are costs assigned to the manufacture of
products and recognized for financial reporting when sold. They include direct materials,
direct labor, factory wages, factory depreciation, etc.
Period costs are on the other hand are all costs other than product costs. They include
marketing costs and administrative costs, etc.
Direct materials: Represents the cost of the materials that can be identified directly
with the product at reasonable cost. For example, cost of paper in newspaper printing,
etc.
Direct labor: Represents the cost of the labor time spent on that product, for example
cost of the time spent by a petroleum engineer on an oil rig, etc.
Manufacturing overhead costs: Represents all production costs except those for
direct labor and direct materials, for example the cost of an accountant's time in an
organization, depreciation on equipment, electricity, fuel, etc.
Conversion costs are all costs incurred to convert the raw materials to finished products and
they equal the sum of direct labor, other direct costs (other than materials) and
manufacturing overheads.
Variable costs are costs which change with a change in the level of activity. Examples
include direct materials, direct labor, etc.
In contrast to sunk costs are opportunity costs which are costs of a potential benefit
foregone. For example the opportunity cost of going on a picnic is the money that you
would have earned in that time.
1. Simplicity: It must be simple, flexible and adaptable to the changing conditions. And it
must be easily understandable to the personnel. The information provided must be in the
proper order, in right time and to the right persons so as to be utilized fully.
3. Economy: The costing system must suit the finance available. The expenditure must be
less than the benefits derived from the system adopted.
7. Less Clerical Work: Printed forms will involve less labor to fill in, as the workers
may be a little educated. They may not like to spend much time in filling the forms.
9. A Sound Plan: There must be proper and sound plans to collect, to allocate and to
apportion overhead expenses on each job or each product in order to find out the cost
accurately.
12
(b) Control of labour cost
It can be controlled if workers complete their work within the standard time limit.
Reduction of labor turnover and idle time to help us, to control labor cost.
(e) Budgeting
Now-a-days detailed estimates in terms of quantities and amounts drawn up before the start
of each activity. This is done to ensure that a practicable course of action can be chalked out
and the actual performance corresponds with the estimated or budgeted performance. The
preparation of the budget is the function of Costing Department.
(h) Expansion:
Cost Accounts may provide estimates of production of various levels on the basis of which
the management may be able to formulate its approach to expansion.
13
(i) Arriving at decisions
Most of the decisions in a business undertaking involve correct statements of the likely
effect on profits. Cost Accounts are of vital help in this respect. In fact, without proper cost
accounting, decision would be like taking a jump in the dark, such as when production of a
product is stopped.
Rupees
The proposed plan is based on the assumption of 50% Debt and 50% Equity. However this
composition of Debt and Equity can be changed as per the requirement of the Investor.
14
Table: Project Viability
IRR % - age 23.41 %
NPV @ 20 % Rs. 4,662,111
Pay Back Period 4-Years
Proposed Location: The said project can be started in any Industrial Area. It is
recommended to establish the Project in an area where Raw Material is easily available. It
may have any Industrial Area of Islamabad. The location of this proposed plan
recommended at Humak Model Town, Islamabad.
15
PRODUCTION PROCESS:
Washing and
rinsing of potato
Flavoring/ salt chips in hot
Potato Frying
on fried chips water for
excessive starch
removal
Packing of
Crisps into
packets of
different sizes
Machinery Requirement:
Following table shows the machinery & equipment requirement for setting up a Potato
Chips Manufacturing Unit imported from China. (HS Codes 84.38.)
Machine Price $ Make Unit RUPEES
Description
Washing Machine 2,450 China 1 146,982
Peeling Machine 2,723 China 1 163,350
Slicing Machine 1,991 China 1 119,460
Chips Washing 5,240 China 1 314,424
Machine
16
Frying Machine 13,885 China 1 833,118
Flavoring machine 5,280 China 1 316,800
Chips Cooling 4,574 China 1 274,428
Machine
Packing Machine 5,718 China 1 343,068
Gas Burning 17,992 China 1 1,079,496
Boiler
Frozen Machine 51,051 China 1 3,063,060
Total 110,903 6,654,186
Other charges
Income Tax 6% 399,251
Freight & 5% 352,672
Handling Charges
as % of CIF price
Installation 1% 74,061
Charges as % of
Price
Cost of Imported 7,480,170
Machinery
Cold Storage 3,000,000
Equipments &
Accessories
TOTAL 10,480,170
Major Suppliers:
17
Office Equipment
Computers 6 3 180,000
0
,
0
0
0
Printers 3 2 75,000
5
,
0
0
0
Photocopy Machine 1 10 100,000
0,
00
0
Fax Machine 1 1 10,000
0
,
0
0
0
Telephone Sets 10 5 5,000
0
0
370,000
Fittings &
Installations
Air Conditioners 4 2 80,000
0
,
0
0
0
Generator 1 1,50 1,500,000
0,00
0
Air Compressor 1 1,20 1,200,000
0,00
18
0
Transformer 1 450, 450,000
000
Electric Installations 300,000
& Charges
Water Pump 500,000
including boring
4,030,000
Furniture & Fixtures
Office Furniture 1 250, 250,000
000
TOTAL 4,650,000
Motor Vehicles:
The proposed project will also be using two Loader truck for transportation purposes.
The truck will be costing Rs. 1,100,000 and the depreciation will be charged at the
rate of 20% on written down value basis. In addition to the above the proposed project
will also be using two Cars costing Rs. 1,000,000/- each.
Pakistan is a Potato growing country and has a major advantage of availability and
lower prices. Potatoes produced in Pakistan are appropriate and ideal to produce
Quality Potato Chips.
Potatoes
Vegetable Ghee / Cooking Oil
Flavors
Utilities Requirement:
20
Utilities required for a Chips Manufacturing Unit are Electricity, Water and
Telephone.
22
Marketing Cost 2,052,000
Other Benefits 524,000
TOTAL 2,576,000
KEY ASSUMPTIONS:
Project Assumptions
%
Equity 5
0
%
Annual Mark Up Rate (Short Term & Long Term) 1
5
%
Debt Tenure in Years 5
General Inflation Rate 5
Operating Assumptions:
23
Maximum capacity utilization 95 %
Revenue Assumptions
Distribution Distributi
price to on price
to
Retailer
Consume
r
Rs. Rs.
Sales Price per
15 gm packet 3.75 5
Raw Material Costs during the 1st Year of Operation Cost (Rs./kg)
Potatoes per Kg 18
Frying Oil per Liter 60
Flavors per kg 392
Region wise Average Annual wholesale prices of Potato (Rs. per 40 kgs)
*
Potato price per kg is Rs. 18 average out by taking different Mandi rates. [Source Market Committee]
Expense Assumptions
Turnover Assumptions
FINANCIAL ANALYSIS:
Projected Income Statement:
2 2 2 2 2 20
0 0 0 0 0 26
2 2 2 2 2
1 2 3 4 5
Current
Assets:
Stock in 6,494,226 7,346,6 8,080,70 8,897,996 9,809,325 10,822,260
Trade 90 9
26
Stores & 1,979,913 2,830,2 3,121,93 3,445,748 3,804,076 4,199,922
Spares 64 1
Advances, 537,000 590,70 649,770 714,747 786,222 864,844
Deposits & 0
Other
Receivables
Accounts 8,726,659 10,040, 11,116,4 12,302,963 13,621,39 15,082,652
Receivable 063 35 7
Cash in 64,243 8,064,2 17,272,1 28,630,897 42,332,72 62,281,375
Hand / Bank 38 73 7
Owner’s
Equity:
Capital 22,000,000 27,341, 36,995,6 47,179,089 59,957,56 75,495,816
Introduced 483 64 3
Profit for the 5,327,398 9,654,1 14,183,4 17,178,474 20,378,25 24,891,002
Year 82 24 3
27,341,483 36,995, 51,179,0 64,357,563 80,335,81 100,386,818
664 89 6
Less ; - - 4,000,00 4,400,000 4,840,000 5,324,000
Drawings 0
27,341,483 36,995, 47,179,0 59,957,563 75,495,81 95,062,818
664 89 6
Long Term 13,200,000 8,800,0 4,400,00 - - -
Loan 00 0
Current
Liabilities:
Current 4,400,000 4,400,0 4,400,00 4,400,000 - -
Portion of 00 0
Long Term
Loan
Accounts 5,728,202 6,259,1 6,919,63 7,658,077 8,478,879 9,388,502
Payable 63 3
Provisions & 4,990,501 5,489,5 6,038,50 6,642,357 7,306,593 8,037,252
Accrued 51 6
Charges
27
References:
[1] https://xplaind.com/209931/cost-classifications#:~:text=In%20managerial%20accounting%2C%20costs%20are,
(for%20decision%2Dmaking).
[2] https://freebcomnotes.blogspot.com/2017/03/an-ideal-costing-system-characteristics.html
[3] https://www.preservearticles.com/cost-accounting/importance-of-cost-accounting-to-business-concerns/3085
[4] http://amis.pk/pdf/feasibilities/potato%20chips%20manufacturing%20unit.pdf
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