Академический Документы
Профессиональный Документы
Культура Документы
Objectives
Outline the elements of a basic cost sheet of a garment.
Describe cost plus method of pricing the garments.
Prepare final Absorption Costing chart, Marginal Costing chart and Activity
Based Costing chart.
Apparel costing is useful for Budgeting and for setting standards for
Measuring Efficiencies. It allows the best use of limited resources and is an
instrument of Management Control. It helps in Cost Audit, and Price
Determination. It ascertains the cost per unit of different products
manufactured and provides a correct analysis of cost both by process and
operations. It discloses sources of wastages and acts as a guide to price
fixation of products manufactured. It ascertains the profitability of each
product that is manufactured and exercises effective control of stocks of raw
materials at various stages. Implements cost control systems. It guides the
management in the formulation and implementation of incentive bonus plans
and helps in preparation of budgets and also helps in implementation of
budgetary control.
III. Elements of Costs
There are three main elements of costs. They are: Materials, Labour and
other expenses. Materials can be either direct material or indirect material.
Labour can be direct or indirect. Other expenses can be direct or indirect.
All Indirect Expenses give rise to Overhead expenses.
This includes: Production or Works overheads, administration overhead,
selling overhead, distribution overhead, research and development
overhead.
1. Direct Materials
Direct materials include: All raw materials, materials specifically purchased,
parts or components purchased or produced, and primary packing materials.
2. Direct Labour
Direct labour includes: Labour engaged on the actual production, labour
engaged in aiding the manufacture, and specially required for production. For
example, Inspectors.
3. Overhead
Overhead is the aggregate cost of indirect materials, indirect materials.
4. Division of Costs
Here are some ways that costs can be divided.
1. Prime Cost = Direct Materials + Direct Labours + Direct Expenses.
2. Works or Factory Cost = Prime Cost + Works or Factory Overheads.
3. Cost of Production = Works Cost + Administration Overheads.
4. Total Cost / Cost of Sales = Cost of Production + Selling Overhead +
Distribution Overhead.
2. By Functions
Cost can be classified by functions. Either by: Manufacturing and Production
Cost, or by Commercial Cost. This includes: (1) Administrative Cost. (2)
Selling and Distribution Cost and (3) Research and Development Cost.
4. By Variability
Costs can be classified by variability, such as: Fixed or Period Cost, Variable
or Product Cost and Semi-variability Cost.
5. By Controllability
Costs can be classified by controllability. These are: Controllable costs and
Uncontrollable costs.
6. By Normality
Costs can be classified by normality. These are: Normal costs and Abnormal
costs.
7. By Time
Costs can be classified on the basis of time. These are: Historical costs and
predetermined costs.
Fabric
Fabric is generally the most significant factor in costing of garment. Fabric
accounts for 60 to 70% of the total cost of basic-styled garments. In many
cases, evaluating the quality and the quantity of fabric consumed in the
garment indicates better than any other factor, the cost of producing it. The
cost of fabric depends upon the type of fabric that is going to be utilised in
the garment.
The types of fabrics are: Woven / knitted fabric, power loom /automatic loom
fabric, fibre / yarn / fabric dyed fabric, fibre content of fabric, such as cotton,
wool, polyester, silk, blended fabric etc., type of dyeing and finish used,
gram per square meter / weight of fabric, type of yarn used, such as ring
spun, open ended, or carded / combed etc.
Parameters that Affect the Fabric Cost
They are: Unit of measurement (UOM), fabric Minimum order quantity (MOQ),
order quantity, Incoterm used.
The unit of Measurement (UOM) is a quantity used as a standard of
measurement. The Unit of Measurement for woven fabric is normally in
meters or yard, while knitted fabric measured in Kilograms or some time it is
in yards also. The merchandiser should aware of unit of measurements while
finding out the cost of fabric. Sometimes a buyer specifies the UOM of fabric.
Incoterm Used
Incoterm used is a factor that makes a huge difference in fabric cost. While
importing the fabric from another country, a merchandiser needs to deal with
the supplier for delivery of the fabric on the basis of incoterms like EXW,
FOB, CIF, DDP etc., based on which it will be decided, as to who will bear the
cost of transportation and risk.
No matter which incoterm is used, all the cost needs to be charged to buyer.
If the fabric is purchased by using EXW incoterm, then the merchandiser
needs to add the transportation cost along with the custom clearance
charges and the price of fabric while calculating the garment cost.
The marker efficiency considered 80-85% depending upon the fabric type i.e.
solid dyed, stripe, checks fabric. Efficiency can be changed depending upon
the fabric parameters, matching parameters of the buyer, type of style.
Trims
Trims include all materials other than fabric used in the garment. For
example, most garments have accessories such as threads, buttons, zippers,
labels, elastics and miscellaneous items. Quality and quantity of trim and
labour required to apply it on garment are directly related to cost of garment.
The different trims have different UOM; even same trim can have 2-3
different UOMs that can be summarised as:
UOM of Trims Used in UOM
Garments Trims
Thread 6000 meter tube,
Meter Cone
Labels Unit
Zippers Unit
Apparel costing in the garment making process is one of the most complex
procedures. There are lot things that go into pricing a single piece of
clothing. Purchasing of raw materials, cost of dyeing, knitting, printing,
transport cost, packaging, banking charges, overheads and cost of trims and
accessories used all are included in it. The merchandiser and the top
management of a company are actively involved in deciding the cost of a
garment.
Fabric consumption
For knitted garments, the Gram Square Meter (GSM) of the fabric plays a
vital role in costing. The type of machines, fabrics & blends, and
configurations used for knitting the fabric of the garment affects the price of
making. Similarly for woven apparels, the Ends per Inch (EPI) are taken into
account. The bigger the beaming length, the lesser will be the cost of
weaving. Hence, the beam size can increase or decrease the cost of making
a garment. The kinds of weave like twill, satin, and plain and the sort of
machineries used for the particular garment influence the weaving cost.
Dyeing cost
The use of a particular kind of dye and a certain shade of color impacts the
dyeing cost of a garment. For example dyeing a fabric in lighter shades costs
less and VAT dyes are costlier than reactive ones. Dyeing of specific colors
like red and turquoise cost more than basic colors like black and white.
Besides the fabrics, trims and accessories used to make the complete
garment such as zippers, buttons, sewing threads, embellishments, care
labels, elastics, and cartons add up to the cost. Threads used in a garment
depend on the kind of seam used in it. There are various ways to measure
the amount of thread being used. At times, the amount of thread used is
calculated at the sample making stage itself. The weight of the thread cone
is measured before and after using the quantity, and the difference is
calculated to identify the amount actually consumed. The size, shape, and
material used in trims like zippers, buttons, and labels also sums up the cost
of making a garment.
Out of the ordinary processes carried out by the manufacturer like washing,
printing, and embroidery for the order of a particular buyer. Wet processing
chemicals consist of bleaching, softening, and neutralizing processes. Unique
and advanced finishes for fabrics can increase the cost of making a garment.
Marginal costing:
Marginal costs are variable costs consisting of labor and material costs, plus
an estimated portion of fixed costs (such as administration overheads and
selling expenses). In companies where average costs are fairly constant,
marginal cost is usually equal to average cost. However, in industries that
require heavy capital investment (automobile plants, airlines, mines) and
have high average costs, it is comparatively very low.
3. Absorption costing:
A method of costing a product in which all fixed and variable costs are
apportioned to cost centers where they are accounted for using absorption
rates. This method ensures that all incurred costs are recovered from the
selling price of a good or service. Also called full absorption costing. See also
direct costing, marginal costing.
Types of Label:
1. Main Label: Contains buyer name or brand name.
2. Size Label: Contains garments size.
3. Care Label: Provides information about washing, ironing, drying
etc.
4. Integrated Label: Contains main label, care label, and size
label in a combination.
Fig 3: Main label: Contain brand
name or buyer name
Trims:
The size of button is express as ligne where 1Ligne = 0.635m. At 1st button
diameter is measure through slide calipers & converted in to ligne.
According to the number of hole button can be classified as two types-
Accessories and Packaging:
Price tag is something that indicates the price being charged for an item.
Total 45.83
6. Packaging
i. Plastic Bag 1 5 5
ii. Carton
a. Inner 1 9 9
b. Oute 1 80 6.6
r (12
trousers
1 ) 0.5
iii. Tags 0.5
Total 21.1
Cost of Labour
Particulars Estimated Level of Cost/min or Cost/piece
SAM Skill unit
1. Inspection 0.28 Skilled 3.5 1
2. Spreading 0.2 Skilled 3.5 0.7
& Marking
3. CMT 0.1 Skilled 3.5 0.35
4. Sewing 22.3 Skilled 3.5 78.05
5. Finishing 0.5 Skilled 3.5 1.75
Total 82.2
Overheads Apportionment per piece
Particulars Basis of Unit Cost/unit Tota
Apportionme l
nt
Factory Overheads
1. Indirect Material
i. Consumable Number 10 0.5 5
ii. Oil
grease/lubrica Millilitres 2 0.5 1
nts
2. Indirect Labour 50 3000/12480 12
i. Wages No. of min
ii. Managers Employees
Salary
3. Indirect Expenses
i. Factory Rent 200*20 50000 1.25
and taxes Floor Space 0
(m2) 100000*5%
ii. Depreciation / 5
iii. Lighting Cost of 5% 1000
Machine 100 100000 0.25
12480
Light Points
Total 24.5
Absorption Costing
Particulars Amount Total
(INR) (INR)
1. Direct Material
i. Fabric 252.00
ii. Lining Fabric 210.11
iii. Trims 47.8
iv. Thread
Consumption 171.79
v. Fusing Material 45.63
A. Material
Consumed 727.33
2. Direct Labour
Inspection 1.00
Spreading & Marking 0.70
Cutting
Sewing 0.35
Finishing 78.05
1.75 82.2
3. Direct Expenses
i. Packaging 21.1 21.1
Costs
B. Prime Cost
(1 + 2 +3) 830.63
4. Factory Overheads 24.5
C. Works Costs 855.13
5. Office and
Administrative 12
Overheads
C. Office and
Administrative
Costs 867.13
(A + B + C)
4. Selling and
Distribution 15
Overheads
D. Total cost of
Sales 882.13
(A + B + C)
E. Profit (140%) 1234.982
F. Sales
(D + E) 2117.112
Marginal Costing
Particulars Amount Total
(INR) (INR)
A. Sales 2117.112
B. Variable Cost
Direct Material
i. Fabric 252.00
ii. Lining Fabric 210.11
iii. Trims 47.8
iv. Thread
Consumption 171.79
v. Fusing Material 45.63 727.33
Direct Labour
Inspection 1.00
Spreading & Marking 0.70
Cutting
Sewing 0.35
Finishing 78.05
1.75 82.2
Direct Expenses
ii. Packaging 21.1 21.1
Costs
Selling and Distribution
Expenses 15
C. Contribution 1271.382
(A - B)
D. Fixed Costs
Factory 24.5
Overheads
E. Profit 1246.882
Activity based costing
Activity Cost driver Cost driver Resource used by
base rate(Rs.) one unit
Factory floor Foot2 - 1.25
space
Electricity Kilowatt - 0.25
Water Gallons - 0.10
Quality control Units inspected 8000/8000p 1
cs.
Packaging - Number of 9 9
inner products
Packaging - Boxes 80 (12 6.6
outer trouser)