As stated, where production flows on in an endless stream the process method is usually employed, often withoutanyformal productionorder. While arecordis
kept of allexpenditures that affect costs, these costs are not determined orappliedto theproductuntil "afterthe event," or, in other words, atthe end of the cost period.
On the other hand, under the order method production
is strictlycontrolledby means of orders of variouskinds which are issued before theworkbegins, andthe cost in-
curred by each order follows that particular order so closely that its actual cost to date may readily be deter-
minedatanystage ofitsprogress.
In an order system, however, goods are sometimes manufactured under conditions which closely approxi- mate those of a process factory—the similarity of
method being due to the large quantity of goods of the
same kind covered by the production order. In such cases costs are found by the process method. For ex- ample, in the manufacture of bolts, screws, nuts, and
similar articles, the product is turned out by the million
by means of automatic machinery. Because offrequent changes madein the kind and size of the products, pro- duction is controlled by means of the usual production order, but because of the quantity and homogeneity of thelots, the cost of theproductis usually determinedby
the processmethod.
Aproduct ofthiskind, e.g., a standard size of screw orbolt, is generally astock product and is rarelyif ever
made in quantity on a customer's order. The foremen of the screw machine departments are furnished with production schedules showing the number of thousand
METHODS— SIMPLE PRODUCTS 49 gross of eacharticle that mustbe dehvered to the stock-
room during a certainperiod of time—usually from five
toten days. The foremenreportontheoutput from day
todaysothat the superintendentcanseewhetherthefac- tory is keeping up to its schedule of production and decide when to change the kind of product. Naturally, the length of time for which a department is kept run- ning on any particular production order depends upon
the current demand for that particular product.
Costs forthe order are figured for the periodduring which thescrew machines or any part ofthem have been occupied with that order. Under these conditions of manufacture, one operator usually attends to half a dozenmachinesandhis laborin realityforms partof the overhead of the department. Where all machines in a
department are engaged on one product, the labor cost for the period, plus expense, divided by the output, gives the unit conversion cost. When screws of two or
more kinds are being made on the various machines, the expense must be distributed among the machines so as to ascertain the proportion applicable to the different products. This distribution presents no difficultywhen, as is usually the case, the screw machines in any depart-
mentareall ofthesametype. Theresultingfigures are of course only the conversion cost, and to this must be added the cost of the material to give the total cost of the finished product.
6. Order Method of Production
The routine of production grows in complexity as the product varies in substance, weight, design, and the
number of its parts. Process products are usually uni-
form and for the most part of one substance. Paper pulpis transformed into rolls orsheets, clay into bricks, cottoninto yarn, sisalinto rope, and ifthe units ofarun or of the whole output for any period are of the same
size, shape, and substance, one cannot be distinguished from another. All such units can then with safety be considered to have consumed an equal quantity of ma-
terial, labor, and expense, per process, and costs are
merged and distributed equally over production.
The routine of production begins to take on the na- ture of an order system, with its special material and laborrecords,when the product,though stillofthe same substance, begins to vary in weight and design. The output of a foundry furnishes a good example. The same casting metal flows from the cupola but the cast- ings may vary in both weight and shape. Production orders are now required to indicate to the foremen how many castings of a certain kind and weight are to be made. If the only difference between the various cast- ingsis in theirweight, cost-findingis still simple, for the cost of each order can readily be found by multiplying
its weight (in pounds) by the cost per pound of the cupola charge and adding thefoundry cost. This foun- dry costis obtained by dividing the cost of molding and
core work bythe pounds of good castings produced.
It frequently happens, however, that some castings are niore intricate in design than others and in conse- quence more time is required to prepare the cores and molds. At oncethe production system becomes compli- cated, not only by the necessity of recording the differ- ences in the core-maker's and the molder's time as appliedto different orders, whichmustbe chargedto the
METHODS— SIMPLE PRODUCTS 51
^ 1>
a z D
§
z kJ
Z
Id
i
§
1 g
(?5
„.. ~—
!^ 1
bJ
a X
C?
D
UJ UJ
i<
|3 i
R ~' "* O
N ^
f^
lU
Si a
i
ô z
o
\D
£ s
S o 5
Q g
ft
1 N D
UJ ILJ
= a
kJ i
s O
Ot ao
CO UJ
1^
1 ^%
m
CM
2 51
u3
<
5:
§X 3a
a9 o
orders accordingly, butalsobythenecessity of charging orderswith overheadexpenseinproportiontothe length oftime eachoccupies the operatingactivitiesof the foun- dry. This elaboration of routine and records involves the keeping of job time tickets and the computing of an hourly expense or overhead rate in the core-making and the molding departments, so that direct wages can be charged to the different orders and expense be dis- tributed over them equitably.
The method by which the manufacturing details of such orders are taken care of in a foundry is shown on the production order ofForm 7. This productionorder
issentfirsttotheforeman of the patternroomtoinform him of the kinds and numbers of the patterns wanted and when theyare required. Itthen goesto thefoundry where the patterns are tobe delivered. The date ofde- livery of the patterns appears on the coupon attached to the production order. This coupon is torn off when
the core box and the patterns reach the foundry, and is
returnedto the office as notice that theorder is about to be put into process. This comparatively simple type of production order furnishes every instruction which is
required by the foundry up to the shipping point of the order.
^ REVIEW QUESTIONS
1. Distinguishbetweenthetwomethods ofcost-finding.
2. Give three examples of industries where the process system is
applicable andthree towhichthe ordersystemisbestadapted.
3. What kind of cost system is best suited to the requirements of the extractive industries?
METHODS— SIMPLE PRODUCTS 53
4. What kind of cost system is best adapted to the needs of a shoe factory: paper box factory; lithographing establish- ment; barrel factory; sole leather taimery?
5. How is production controlled in a process factory?
6. Illustrate how costs are figured in a process factory.
7. What kind of cost system is suited to a foundry?
8. What kind of cost system would you install in a laundry, a green house?
CHAPTER V