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Labor Cost Computation & Control Presentation 4
Labor Cost Computation & Control Presentation 4
Labor Cost Computation & Control Presentation 4
Labor
Labor is another important element of cost and for overall cost control
and cost reduction, labor cost is of paramount importance. However,
for control and reduction of labor cost, it is essential to compute the
labor cost in a scientific manner and hence there should be proper
systems and processes and documentation, which will help
computation of labor cost in a scientific manner.
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Md. Jamsedul Islam
Asst. prof
Dept. of THM 9
NSTU
a) Labor Turnover: Labor turnover, which is also called as ‘attrition’ is a major
problem in the modern times (Attrition is the departure of employees from the
organization for any reason (voluntary or involuntary), including resignation,
termination, death or retirement).. Labor turnover can be defined as, a change in
the labor force as compared to the total labor force. Labor turnover is prevalent in
every industry, however, the proportion of the change vary from industry to
industry. For example, turnover in information technology sector is the highest
today due to ample job opportunities due to the rapid growth of this sector. Labor
turnover should not be very high as it will result into double loss to the
organization, the first one is that an experienced employee will be lost and
secondly new person who is replacing the old one, may not have same
qualifications and experience and till he is accustomed to the new job, his
productivity is bound to be low. Similarly suitable training will have to be given to
him in order to acquaint him with the environment, which will also result in
additional expenditure. Due to these reasons, every organization tries to minimize
the labor turnover. However, some proportion of labor turnover is actually
necessary, as it will bring in fresh ideas in the organization. If labor turnover is
reduced to zero, it will indicate that the employees do not have any opportunity
outside and hence they are surviving. Therefore some degree of labor turnover is
always desirable. Md. Jamsedul Islam
Asst. prof 10
Dept. of THM
b) Measurement of Labor Turnover: It is essential for any organization
to measure the labor turnover. This is necessary for having an idea
about the turnover in the organization and also to compare the labor
turnover of the previous period with the current one. The following
methods are available :
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2-Solution:
Cost of labor turnover can be computed by dividing the preventive
cost and replacement cost by the average number of employees.
The computation is shown below:
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2. Disc Method: This is one of the older and manual methods of
recording time. A metal disc bearing the identification number of each
worker is kept at the factory gate or entrance of department. The
worker take their disc and put it on a empty tray or box kept nearby
and the tray then removed after scheduled time and another ‘late box’
or tray is kept in its place which is also removed after the maximum
late time allowed. The time keeper then record the attendance in a
Register which will subsequently be passed to the Payroll
Department. The main limitation of this method is that there is a
possibility of marking the attendance of a worker by his friend i.e. by a
proxy. Secondly if the number of workers is large, there will be a delay
in recording time due to manual operation of this system.
3) Job Ticket: Job tickets are given to all workers where time for
commencing the job is recorded as well as the time when the job is
completed. The job tickets are given for each job and the recording of
the time as mentioned above helps to ascertain the time taken for
each job. After completing one job, the worker is given another job.
4) Job Card: This card is shows the time taken for completion of each
job which a worker does during a day.
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Method Study: Method study is a systematic procedure which subject
each operation to systematic analysis in order to eliminate the
unnecessary operations and to achieve the best method of
performing the operation. Method study is also called methods
engineering or work design.
Steps or Procedure Involved in Methods Study are
1. SELECT the work to be studied and define its boundaries.
2. RECORD the relevant facts about the job by direct observation and
collect such additional data as may be needed from appropriate
sources.
3. EXAMINE the way the job is being performed and challenge its
purpose, place sequence and method of performance.
4. DEVELOP the most practical, economic and effective method,
drawing on the contributions of those concerned.
Motion study is part of method study where analysis of the motion of
an operator or work will be studied. Work measurement is also
called by the name ‘time study’. Without work measurement data,
we are not in a position to determine the rate of production and
also labor utilization and efficiency. It may not be possible to
introduce incentive schemes and standard costs for budget
control.
Therefore, Work Study includes the application of motion study and
time study. Time study determines the Standard time that should be
taken for completing a particular job under standard or normal
working conditions. For fixation of standard time, motion study is
necessary. Thus, the motion study precedes the time study.
Motion Study and Time Study involves the following steps:
dividing the job into fundamental operations and studying them in
detail to eliminate the unnecessary elements or motions.
After investigation all movements in a job, process or operation, the
motion study aims at finding out the most scientific and systematic
way of performing the job.
After eliminating unnecessary motions, the normal time that should
be taken to perform these motions is decided with the help of a stop-
watch.
When the normal time so fixed, some allowance is added to the
normal time which is due to fatigue, change of job, change of tools
and so on.
Thus standard time or a job or process is determined.
Time and Motion Study takes into consideration not only the human
element in the job but also materials, plant and machinery, tools and
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equipments etc, to be used.
The benefit of time and motion study are as follows:
A. To develop incentive wage schemes which require data about the
time allowed and time taken for a particular job.
B. To improve utilization of men, machines and materials.
C. To assist in production control
D. To assist in setting labor standards
E. Cost control and reduction.
Example 1: The time study engineer observes that average time taken
by a worker to perform a job is 30 minutes. It has been also decided to
allow 5% for fatigue allowance, 3% for interference and 2% for
personal needs. Determine the standard time to perform the job?
Solution: Normal Time = 30 minutes
ADD: Allowance for:
Fatigue 5% =1.5 minutes
Interference 3% = 0.9 minutes
Personal needs 2% = 0.6 minutes
----------------------------------------------------------------------------
Standard Time = 33 Minutes
EXAMPLE 2: Following data were obtained by a work study.
(i) Maintenance time:
(a) Get out and put away tools = 12.0 min/day
(b) Cleaning of machine = 5.0 min/day
(c) Oiling of machine = 5.0 min/day
(d) Replenish coolant supply = 3.0 min/day
(ii) Interruption:
(a) Interruption by foreman = 5.0 min/day
(b) Interruption by porter etc. = 4.0 min/day
(iii) Delay time due to power failure etc. = 6.0 min/day
(iv) Personal time = 20.0 min/day
Calculate total allowances, total available cycle time productive hours,
considering a working day of 8 hours.
SOLUTION: Total allowance (sometimes also known as station time)
= Maintenance time + Interruption time + Delay time + Personal time
= (12.0 + 5 + 5 + 3.0) + (5.0 + 4.0) + 6.0 + 20.0
= 25.0 + 9.0 + 6.0 + 20.0 = 60 min per day
∴ Total available cycle time = Total work period – Total allowances
= 480 minutes – 60 minutes = 420 min per day
Productive hours = Time Available/ Number of hours
= 420 minutes / 8 hours = 52.5 minutes per hour
[D] JOB EVALUATION: To establish proper wage and salary structure
for various jobs in a scientific manner, it is necessary to determine the
relative value of jobs and hence a job evaluation is done. Job
evaluation is a technique of analysis and assessment of jobs to
determine their relative value within the firm. It aims at providing a
rational and equitable basis for differential salaries and wages for
different classes of workeRS.
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B] Time Rate At High Wage Levels: In this system, workers are paid at
time rate but the rate is much higher than that is normally paid in the
industry or area. In this method, overtime is not normally allowed.
This method offers a very strong incentive to workers and it can
attract talented workers in the industry. However, care should be taken
that productivity also increases, otherwise the cost will go on
increasing.
A] Straight Piece Rate: In this method, rate per unit is fixed and the
worker is paid according to this rate.
Wages= Number of Units X Rate Per Unit
For example, if the rate per unit is fixed at RS.10 and the output
produced is 300 units, Wages =e RS.10 X 300 units = RS.3,000.
The method is simple and provides a very strong incentive to the
workers by linking the monetary reward directly to the results.
Productivity can be increased substantially if the rate of pay
includes a really adequate incentive.
Higher productivity will result in lowering the cost per unit.
However, the main limitation of this method is that if a worker is not
able to work efficiently due to reasons beyond his control, he will be
penalized in the form of lower wages.
QS: Hourly rate of pay Rs 2 per hour, Standard Time per unit is 90 minutes
(ascertained by time and motion study). What is the piece rate:
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Solution: Piece Rate = (Rs 2/ 60 minutes) X 90 minutes = Rs 3 per unit
B] Differential Piece Rates: Under these methods, there is more than
one piece rate to reward efficient workers and to encourage the less
efficient workers or trainee to improve. In other words, earnings vary
at different stages in the range of output.
For deciding the efficiency, comparison is made between the standard
production and actual production of the worker. If the actual
production is more, the worker qualifies for higher rate of wages. The
differential piece rates methods will be useful when the production is
of repetitive type, methods of production are standardized and the
output can be identified with individual workeRS.
The following are the major systems of differential piece rate system:
i] Taylor
iiI] Merrick
Differential to be applied:
80% of piece rate when below standard
120% of piece rate at or above standard
Comment: Labor cost increases from Rs1.20 per unit to RS.1.80 per
unit. Taylor’s system is resisted on this ground as well as on the
ground that it is very harsh on the workers as it does not guarantee
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minimum wages.
ii] Merrick Differential Piece Rate System: Merrick’s system is
modification of Taylor’s system and is comparatively less harsh on
the workeRS. It is particularly useful to beginners and also offers an
incentive who have potential of higher productivity. The scale of
remunerations is as follows:
50
QS-5:X, Y and Z are three workers working in a manufacturing
company and their output during a particular 40 hours week was 96,
111 and 126 units respectively. The guaranteed rate per hour is RS.10
per hour. High piece rate is RS.6 per unit. Standard production is 100
units per week. Compute the wages or earnings of each worker and
labor cost per unit under Taylor, Merrick & Gantt Task & Bonus Plan.
5-Solution:
In 40 hours standard output = 100 units
In 1 hour standard output =(100 units / 40 hour) =2.5 units per hour
Normal Piece Rate=(Rs 10 per hour/2.5 units per hour) = Rs 4 per unit
Worker Y: Wages = 111 units X Rs4.8 = Rs 533 [Y will get the wages at
120% of normal piece rate as his output is above standard]
Worker Z: Wages = 126 units X Rs 4.8 = Rs605 [Z will also get the
wages at 120% of normal piece rate as his output is above standard]
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Merrick Plan: Standard Output is 100 units
Worker X = actual output is 96, this means efficiency level is 96%. As
per Merrick Plan, wages of X will be 110% of normal piece rate which
is (Rs 4 X 1.1)=Rs4.4 per unit
Wages = Rs 4.40 X 96 = Rs 422
Worker Y = actual output is 111 units, efficiency level is 111%. As per
Merrick Plan, wages of Y will be 120% of normal piece rate which is
(Rs 4 X 1.2)=Rs4.80 per unit
Wages = Rs 4.80 X 111 = Rs 533
Worker Z = actual output is 126 units, efficiency level is 126%. As per
Merrick Plan, wages of Z will be 120% of normal piece rate which is
(Rs 4 X 1.2)=Rs4.80 per unit
Wages = RS.4.80X 126 units = Rs 605
QS-6 (a): Time allowed for a job is 48 hours; a worker takes 40 hours
to complete the job. Time rate per hour is Rs 15. Compute the total
earnings of the worker using Halsey Premium Scheme.
QS-6 (c): Time allowed for a job is 10 hours; a worker takes 8 hours to
complete the job. Time rate per hour is Rs 2. Compute the total
earnings of the worker using Rowan Scheme.
Solution: Rowan Scheme
Earnings or Wages =(H X R) + [S – H /S] X( H X R)
=(8 X Rs 2)+ (10 – 8/10) x (8 X Rs 2)
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=Rs 16 + Rs 3.20 = Rs 19.20
QS-6 (d): Time allowed for a job is 5 hours; time rate per hour is Rs 2.
Compute the wages payable under Barth Scheme when time taken by
worker X is 5 hours, worker Y is 6 hours and Worker Z is 4 hours
respectively to finish the particular job
Solution: Barth Scheme
Earnings or Wages= Rate per hour X √ (Standard hours X Actual hours
worked)
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B] Group Bonus Scheme: Many times output of individuals cannot be
measured. Similarly, the output of individual is dependent on the
combined effort of group. In such cases, usually group bonus system
is implemented. The total amount of bonus, which is determined
according to productivity, can then be shared equally or in agreed
proportion between the group membeRS. The various group bonus
schemes are discussed below:
Since, the ratio of Labor cost to value added is reduced by 1%, hence
the bonus payable to all employees is= 1% of Rs 4,50,000 = Rs4500
Md. Jamsedul Islam
Asst. prof
Dept. of THM 61
NSTU
c) Scanlon Plan: This method is similar to the Rucker plan as
discussed above except that the ratio of labor cost to the sales value
of production is taken instead of labor cost to value added.
d) Towne Gain Sharing Plan: In this method standards are set for
labor cost. If there is a saving in the costs, 50% of ‘gain’ (savings in
cost) is paid to workers on pro-rata basis in addition to their basic
wages.
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QS-9. Calculate the normal and overtime wages payable to a workman
from the following data
RS.1080
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QS-10. A worker takes 6 hours to complete a job under a scheme of
payment by results. The standard time allowed for the job is 9 houRS.
His wage rate is RS.15 per hour. Material cost of the job is RS.120 and
the overheads are recovered at 15% of the total direct wages.
Calculate the factory cost of job under
a] Rowan and
b] Halsey system of incentive system.
Solution:
a] Rowan Scheme: Earnings or Wages = H X R + [S – H /S] X H X R
= 6 hrs X RS.15 + [9 – 6/9] X 6 XRS.15
= RS. 90 + 1/3 X RS.90
= RS.120
A will get wages as per the normal piece rate as his efficiency level is
81.25% which is below 83%, 71
Hence his wages will be 390 units X Re.0.090 = RS.35.10
Wages under Merrick’s Differential Piece Rate System
Worker A:
Standard production = 8 hours X 60 units = 480 units
B will get wages @ 110% of normal piece rate, i.e.Re.0.099 per unit
His wages = RS.0.099 X 450 units = RS.44.55
Worker C:
Efficiency level = 600 /480 x 100 = 125%
B will get wages @ 120% of normal piece rate i.e. Re.0.108 per unit
74
QS-13. Calculate total monthly remuneration of three workers, A, B
and C from the following data.
[a] Standard production per month per worker – 1000 units, actual
production during the month, A 850 units, B 750 units and C 950
units.
[b] Piecework rate RS.10 per unit [actual production]
[c] Additional production bonus is RS.10 for each percentage when
actual production exceeding 80%
[d] Dearness pay fixed Rs 50 per month.
* NOTE: As per the example, bonus will be paid only if the efficiency
exceeds 80%. For A and C the efficiency exceeds 80% and hence they
will be entitled for a bonus of RS.10 per percentage exceeding 80%. B
will not be entitled for any bonus as his production efficiency does
not exceed 80%.
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QS-14. The standard hours for job X is 100 houRS. The job has been
completed by Amar in 60 hours, Akbar in 70 hours and Anthony in 95
houRS. The bonus system applicable to the job is as follows.
The rate of pay is RS.10 per hour. Calculate the total earnings of each
worker and also the rate of earnings per hour.
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Solution-14: Statement showing total Earnings and Rate of Earnings
per Hour
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# Rate of wages per hour is computed by dividing the total wages by
the total number of houRS.
For the year 2006-07, the sales revenue has been RS.3, 25, 000 and the
total salaries and wages paid RS.90, 000. What is the amount due to
employees under Scanlon Plan? If 50% is set-aside in the bonus
equalization reserve fund, how much money is to be paid out for 2006-
07 as Scanlon Bonus? 80
Solution-15
Average annual salaries and wages
= [RS.72, 000 + RS.70, 000 + RS.86, 400]/3
= RS.76, 133
Average annual sales revenue
= [RS.2, 40, 000 + RS.2, 50, 000 + RS.2, 70, 000]/3
= RS.2, 53, 333
Scanlon Plan: Bonus percentage (labor cost to sales revenue)
= RS.76, 133 / RS.2, 53, 333 = 30.05%