Chapter 15 Learning Curve
Chapter 15 Learning Curve
Chapter 15 Learning Curve
CHAPTER 15
LEARNING CURVE
CHAPTER INDEX
CONCEPT
LEARNING CURVE RATIO
LEARNING CURVE EQUATION
ASSUMPTIONS
DISTINCTIVE FEATURES OF LEARNING CURVE THEORY
APPLICATIONS OF LEARNING CURVE
LEARNING CURVE IN PRICING DECISIONS
LIMITATIONS OF LEARNING CURVE
THEORETICAL QUESTIONS
15.1 CONCEPT
Learning Curve technique is applied for the estimating the labour hours required for the
production of goods (or supplying the services) in the companies which undertake non-
repeat orders. The production is carried according to customer’s specifications and the
order size varies as per the customer’s requirements. As the order size increases, the
average time per unit of output tends to decline. This is because the workers become more
familiar with the tasks that they perform, they learn from their errors, they find new ways
to complete tasks more efficiently, so less time is required for the production of each
subsequent unit.
The learning curve is not a cost reduction technique. It focuses on a naturally occurring
phenomenon. It is based on the proverb that practice makes a man more efficient.
Studies have shown that the average time per unit/batch reduces at a constant rate as
production quantity increases. The underlying premise of this technique is that as the
production doubles, the average hours per unit required to complete a unit/batch of
production are reduced at a constant rate. For example, if in a company, the learning curve
is 80 per cent, this would indicate that as the production doubles, the average hours per
unit for a batch of production will be 80 per cent of the hours for the previous batch. For
2
example, if production of 1 unit requires 100 hours and learning curve is 80% then time
required for different levels of production will be as follows:
Level of Production Hour per unit Total Hours
1 unit 100 100
2 units 80 160
4 Unit 64 256
8 units 51.20 409.60
16 units 40.96 655.36
The table shows that the average time per unit declines rapidly in beginning, then slowly
and eventually the decline will be so small that it can be ignored. When no further
improvement is expected and the regular efficiency level is reached, the situation is
referred as steady-state production level. When this state is reached, each unit takes the
same amount of time as the last one, thus the marginal time per unit is constant. Total time
will continue to rise but average time for total production will continue to fall at reduced
rate.
When Yx is cumulative average time required to produce X units (or batches), a is the time
required to produce the first unit (or batch) of output and X is the number of units (or
batches) of output under consideration.
Q. No. 15.1 Your company has been approached by a customer to supply four units of a
new product made to the customer’s individual specification. The company experiences a
90 per cent learning rate. The estimated labour time for the first unit of this product is 1.50
hours and the company’s direct labour cost is Rs.5 per hour (a) Estimate the labour cost of
this order (b) After receiving the first order, if the customer places a repeat order, what will
be the labour cost for the second order, (c) If the costumer had ordered all eight units at the
same time, calculate the labour cost per unit for the combined order.
Answer
Level of Production Average Hours per unit Total Hours
1 1.50 1.50 hours
2 1.35 2.70 hours
4 1.215 4.86 hours
8 1.0935 8.748 hours
Q. No. 15.2 A company developing a new product makes a model for testing and then a
demonstration model and then goes for regular production. The time-taken to make the
model for testing is 300 hours and from past experience of similar models, it is known that
a 90 per cent learning curve applies. Find the average time per unit of two regular
production units.
Answer
Level of Production Average Hours per unit Total Hours
1 (testing model) 300 200
2 (Testing model + demo model) 270 540
4 (Testing model + demo model
+ 2 units of regular production)) 243 972
Total time for 2 regular production units: 972 – 540 = 432
Average time for 2 regular production units: 216
Q.No. 15.3 Engine Ltd. manufactures engine mountings. They have just completed an initial
run of 30 mountings at the following costs.
Direct material 20,000
Direct Labour (6000 hrs) 24,000
Tooling (Re-usable) 3,000
VO (50 p. per hour) 3,000
FO 6,000
56,000
The company has got an order for additional 90 mountings for Rs.1,10,000. Learning curve
is 80 per cent. Should the order be accepted given that the company is short of work?
Answer
Let 30 units = 1 Batch
Level of Production Average Hours per 30 units Total Hours
30 units (1 batch) 6000 6000
60 units (2 batches) 4800 9600
120 units (4 batches) 3840 15360
Total 1,02,120
As the order value exceeds the relevant cost, the order may be accepted.
Q. No. 15.4 A firm produces special goods as per customer’s specifications. It has to quote
the price per unit of a special order. It estimates the following cost structure:
The order will require a special tool costing Rs. 3700 which is chargeable to the customers.
If the order received is for 50 or 100 units, the work will have to be done in the current
month. Department X has already received orders requiring 7,100 hours in the current
Month. Department Y, however, will be working at 90 per cent of capacity.
The company follows a policy of adding the following marks ups on cost for determining
the selling prices:
Department X Department Y Direct Material
22% 15% 5%
Answer
Teaching notes:
5
(i) Department X has a spare capacity of 900 hours. If the order is for 50 units, the
requirement will be of 600 hours. Hence no overtime Premium. If the order is for
100 units, the requirement will be of 960 hours. Overtime Premium will be for
60 hours.
(ii) Department Y has a spare capacity of 600 hours. If the order is for 50 units, the
requirement will be of 350 hours. Hence no overtime Premium. If the order is for
100 units, the requirement will be of 630 hours. Overtime Premium will be for
30 hours.
VO 630 x 1.50
FO 630 x 5.00
Total 7,395 7,395
Total cost 37,105
Mark up :
Materials 607.50
X 3049.20
Y 1,109.25
Total 4,765.95 4,765.95
Sales 41,870.95
Selling Price 41,870.95/100 = 418.71
(c) In this case 100 units will be made towards end of the current month. (This will
require payment of overtime of 60 hours by X Department and of 30 hours by Y
Department). Remaining 100 units will be made in the beginning of the next month
when there is no capacity limitation. Hence, no overtime premium)
Determination of Selling Price per unit for the additional order of 100 units
Rs.
Sales value of 200 units 68,296.93
Sales Value of first order of 100 units 41,870.95
7
Q. No. 15.5 XYZ Company, which has developed a new machine, has observed that the time
taken to manufacture the first machine is 600 hours. Calculate the time which XYZ
Company will take to manufacture the second machine if the actual learning curve rate is
(i) 80% and (ii) 90%. Explain which of the two learning rates will show faster learning.
(CA FINAL Nov. 2008)
Answer:
80% LC 90% LC
Number of Average No. of Total Number Average No. of Total No. of
machine(s) hours of hours hours hours
1 600 600 600 600
2 480 960 540 1080
Q. No. 15.6 M Ltd manufactures a special product purely carried by manual labour. It has a
capacity of 20,000 units. It estimates the following cost structure:
Direct material Direct Labour Variable overheads
Rs.30/ unit Rs.20/ unit (1 Hour/unit) Rs.10/ unit
Fixed overheads at maximum capacity Rs.1,50,000
It is estimated that at current level of efficiency, each unit requires one hour for the first
5,000 units. Subsequently it is possible to achieve 80% learning curve. The market can
absorb the first 5,000 units @ Rs.100/unit. What should be the minimum selling price
acceptable for an order of 15,000 units for a prospective client? (CA FINAL May 2008)
Answer
Let 5,000 units = 1 batch
Total time required for 1 batch (5000 units) = 5,000 hours
Average Time (per batch) required for 4 batches = 5,000 x 0.80 x 0.80 = 3200 hours
Total time for 4 batches (20,000 units) = 12,800 hours
Total time for special order of 15,000 units: 7,800 hours
Q. No. 15.7 PQ Ltd makes and sell a labour-intensive product. Its labour force has a
learning curve of 80%. This rate is not applicable to variable overheads. The cost per unit of
the first product is as follows:
Direct material Direct Labour Variable overheads
Rs.10,000/ unit Rs.8,000/ unit (Rs. 4/ Hour) Rs.2,000/ unit
The company has received an order from X Ltd for 4 units of the product. Another
customer, Y Ltd is also interested in purchasing 4 units of the product. PQ has the capacity
of fulfilling both the orders. Y Ltd presently purchases this product at Rs.17,200/ unit and
is willing to pay this price per unit of PQ’s product. But X Ltd lets PQ choose one of the
following options:
(i) A price of Rs.16,500 per unit for the 4 units it proposed to take from PQ Ltd.
(ii) Supply X Ltd’s idle labour force to PQ, for only 4 units of production, with PQ
having to pay only Re.1 per hour to X Ltd’s workers. X Ltd’s workers will be
withdrawn after the first 4 units are produced. In this case, PQ need not to use its
labour for producing X Ltd’s requirement. X Ltd assures PQ that its labour force
also has the learning rate of 80%. In this option, X Ltd offers to buy the product
from PQ at only Rs.14,000 per unit.
If both orders came before any work started, what is the best option that PQ may
choose? Present suitable calculations in favour of your argument.
(CA FINAL May 2009)
Answer
Working note
Time Requirement
No. of unit(s) Average hours per unit Total hours
1 2,000 2,000
2 1,600 3,200
4 1280 5,120
8 1,024 8,192
Teaching note : In case the idle labour of X is not used, the same set of workers will be
producing all the eight units (total time 8192 hours). Average time per unit will be 1024
hours. In case the idle labour of X is used, two set of workers shall be working and
producing 4 units each set of workers. Each set of workers will 1280 hours per unit. Hence
the total time will be 1280 x 8 = 10,240 hours
Main answer
Calculation of labour cost under each of the two options
Total labour cost for both theorders
I option (Price from X Rs.16,500) 1024 x 8 x Rs.4 = Rs.32,768
II option (Price from X Rs.14,000) 1280 x4 x Re.1 + 1280 x 4 x Rs.4 = Rs.25,600
9
Q.No. 15.8 The Gifts Company makes mementos for offering chief guest and other
dignitaries at functions. A customer wants 4 identical pieces of a hand – crafted item. The
following costs have been estimated for the 1st unit of the product:
It is possible to achieve 90% learning curve. The company’s policy is that one Labour works
for one order. (i) What is the price per piece if the targeted contribution is Rs.1,500 per
piece? If 4 different labourers made the 4 products simultaneously to ensure faster
delivery, can the price at above (i) quoted? Why? (CA FINAL Nov. 2009)
Answer
Time requirement ( One worker completes the order)
No. of unit(s) Average hours per unit Total hours
1 20.00 20.00
2 18.00 36.00
4 16.20 64.80
Q. No/ 15.9 A firm has received an order to make and supply eight units of a product which
involves intricate labour operations. The first unit took 10 hours. It is understood that
Learning Curve is 80%. Wage rate is Rs.12 per hour. What is the total time and labour cost
required to execute the above order? If a repeat order of 24 units is also received from the
same customer, what is the labour cost for the second order? [ICWA Final Dec. 2008]
10
Answer:
Output Laour hours per unit Total Labour hours
1 10 10
2 8 16
4 6.40 15.60
8 5.12 40.96
16 4.096 65.536
32 3.2768 104.8576
Given that a = 10 hours and learning rate is 80 per cent you are required to calculate
(i) Average time for 20 units (ii) Total time for 30 units (iii) Time for units 31 to 40
Given that
log 2 = 0.3010, Antilog of 0.5811 =3.812 log 3 = 0.4771, Antilog of 0.5244 = 3.345
log 4 = 0.6021, Antilog of 0.4841 = 3.049
Answer
(i) Y = ax-0.322
Y = 10.20-0.322
log Y = log10 + log20-0.322
log Y = 1.00 – 0.322log20
log Y = 1.00 – 0.322(1.3010)
log Y = 1.00 – 4189
log Y = 0.5811
(ii) Y = ax-0.322
Y = 10.30-0.322
11
Y = ax –0.1522
Y = 100.9–0.1522
log Y = log100 + log9–0.1522
log Y = 2.00 – 0.1522log9
log Y = 2.00 – 0.1522(0.9542)
log Y = 2.00 – 0.1452
log Y = 1.8548
4 64 ?
Answer:
b = log 0.80/log 2 = [-1 + .9031]/0.3010 = -0.3219
Y = ax–0.3219
Y = 100.3–0.3219
log Y = log100 + log3–0.3219
log Y = 2.00 – 0.3219log3
log Y = 2.00 – 0.3219(0.4771)
log Y = 2.00 – 0.1536
log Y = 1.8464
taking Antilog of both the sides, Y = 70.21
Q.No. 15.13 An order for 30 units has been received by a company. First unit requires 40
hours. 14 units required 240 hours. Can it be concluded that its L.C. is 80 per cent.
Answer:
When 14 units are produced, average time per unit = 240/14 =17.1429
Y = axb
17.1429 = 40.14b
-0.32 = LogLC/log2
-0.32 = logLC/0.301
logLC = -0.0963
Q.No. 15.14 An order for 20 units is received. L.C. is 80 per cent. First unit requires 23.35
hours. Find (a) Total time for 20 units, (b) Total time for additional 40 units.
Answer:
(i) Total time for 20 units
13
Y = axb Y is the average time per unit for x units, b is the learning coefficient,
a is the time for the first unit, x is the cumulative number of units
log 0.8
b = ………… = -0.322 for a learning rate of 80 per cent.
Log 2
Y = axb
Y = 23.35(60)– 0.322
LogY = Log23.35 – 0.322.Log60
LogY = 1.3683 – 0.322(1.7782)
LogY = 0.7957
Q.No. 15.15 The first unit in a batch of 90 took 40 minutes to complete. The whole batch
took 30 hours. Find L.C. percentage.
Answer
Average time per unit for the batch = 30x60/90 = 20 minutes
Y = axb Y is the average time per unit for x units, b is the learning coefficient,
a is the time for the first unit, x is the cumulative number of units
20 = 40(90)b
Log 20 = Log40 + bLog90
1.3010 = 1.6021 + b(1.9542)
B = – 0.1541
14
LogLC LogLC
– 0.1541 = ------------- – 0.1541 = ----------------
Log2 0.3010
Q. No. 15.16 Calculate the average unit cost of making (i) 4 machines, (ii) 8 machines, and
(iii) 12 Machines using the data given below. (a) L.C. 80 per cent. (b) Labour cost Rs. 3
hours, (c) First Machine requires 1000 hours, (d) Material cost Rs. 1800 per machine, (e)
Fixed cost for either size order Rs. 8,000.
Answer
Y = axb
= 1000(12) – 0..322
Q. No. 15.17 A company has 10 direct workers, who work for 25 days a month of 8 hours
per day. The estimated down time is 25% of the total available time. The company received
an order for a new product. The first unit of the new product requires 40 direct labour
hours to manufacture the product. The company expects 80% (index is -0.322) learning
curve for this type of work. The company uses standard absorption costing and the cost
data are as under:
Direct materials Rs. 60 per unit
Direct labour Rs. 6 per direct labour hour
Variable overheads Rs. 1 per direct labour hour
Fixed overheads Rs. 7,500 per month
15
Required:
(i) Calculate the cost per unit of the first order of 30 units.
(ii) If the company receives a repeat order for 20 units, what price will be quoted to
yield a profit of 25% on selling price? [CA Final Nov. 2002]
Answer:
Working note 1:
Fixed overhead recovery rate:
Productive Hours per month = 10 x 25 x 8 x 0.75 = 1500
Monthly Fixed overhead Rs.7500
Fixed overhead recovery rate : Rs.5 per productive hour.
Working note 2:
Y = axb
Y = 40.30 -0.322
Working note 3:
Y = axb
Y = 40.50-0.322
logY = log40 -0.322log50
logY = 1.6021 – 0.322(1.6990)
logY = 1.0550
Y = 11.35
Total time for 50 units = 50x11.35 = 567.50
Time for 20 units = 567.50 – 401.70 = 165.80
Time per unit (repeat order of 20 units) = 8.29
Main Answer
(i) Calculation of cost per unit of the first order of 30 units
Material Rs.60
Labour (13.39 hours @ Rs.6 per hour) Rs.80.34
V.O. (13.39 hours @ Re.1per hour) Rs.13.39
FO (13.39 hours @ Rs.5 per hour) Rs.66.95
Total Rs.220.68
Q. No. 15.18 An electronics firm which has developed a new type of fire-alarm system has
been asked to quote for a prospective contract. The customer requires separate price
quotations for each of the following possible order:
Order Number of Fire-alarm systems
First 100
Second 60
Third 40
The firm estimates the following cost per unit for the first order:
Direct materials Rs.500
Direct Labour :
Deptt. A (Highly automatic) 20 hours at Rs. 10 per hour
Deptt. B (Skilled labour) 40 hours at Rs. 15 per hour.
Determine a price per unit for each of the three orders, assuming the firm uses a markup of
25% on total costs and allows for an 80% learning curve. Extract from 80% learning curve
table.
X 1.0 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
Y% 100.0 91.7 89.5 87.6 86.1 84.4 83.0 81.5 80.0
X represents the cumulative total volume produced to date expressed as a multiple of the
initial order. [CA Final May 2005, May 2010]
Answer:
Total time for Total time for Total time for
100 units (Hours) 160 units (Hours) 200 units (Hours)
A 100 x 20 = 2,000 160x20 = 3,200 200x20 = 4000
B 100 x 40 = 4,000 160x40x0.861 = 5510.40 200x40x0.80 =6400
Statement showing Selling price per unit for each of the three orders
I order II order III order
Material Rs.500.00 Rs.500.00 Rs.500.00
Labour
Department A Rs.200.00 Rs.200.00 Rs.200.00
Department B Rs.600.00 Rs.377.60 Rs.333.60
VO (20% of Direct Labour) Rs.160.00 Rs.115.52 Rs.106.72
FO
A (Rs.8/hour) Rs.160.00 Rs.160.00 Rs.160.00
B (Rs.5/hour) Rs.200.00 Rs.125.87 Rs.111.20
Total cost Rs.1,820.00 Rs.1,478.99 Rs.1411,52
Profit Rs.455.00 Rs.369.75 Rs.352.88
Selling price Rs.2,275.00 Rs.1,848.74 Rs.1,764,40
Q. No. 15.19 BCC manufactures executive chairs. They are considering a new design of a
chair to launch in the market. Proposed selling price is Rs.120. BCC wants a contribution of
20% on selling price. There are 3 direct costs :(1) Frame which is bought from the market
at Rs.51 (2) leather Rs.25.00 per chair (3) Direct labour @ Rs.15 per hour. The first table
will take 2 hours. Learning curve is 95%. Find the minimum number of chairs to be
produced and sold so that the target is achieved. Assume the learning improvement will
stop once 128 chairs have been made and the time for the 128th unit will be the time per
unit for all subsequent units. (Adapted ACCA)
Answer
Output Average time per unit
1 2
2 2 x 0.95 = 1.90
4 1.90 x 0.95 = = 1.805
8 1.805 x 0.95 = 1.71475
16 1.71475 x 0.95 = 1.6290125
32 1.6290125 x 0.95 = 1.5447561875
64 1.5447561875 x 0.95 = 1.4701183781
128 1.4701183781 x 0.95 = 1.396674591
(say 1.3967 hours per unit)
log0.95
equal to ……………. = - 0.0741 for a learning rate of 95 per cent.
Log2
Q. No. 15.20 Time Ltd specializes in the manufacture of electronic watches. Development
on a new watch called Punctual is to start shortly. Development of the product will take I
year. The life cycle of the product is expected to be 2 years. The sales volume is expected as
follows:
Year Sales units
1 80,000
2 2,20,000
Year 1:
19
R&D Rs.10,50,000
Design cost Rs.5,00,000
Marketing cost Rs.11,60,000
Office costs Rs.1,70,000
Total Rs.28,80,000
Years 2 to 3
Year 2 Year 3
Fixed Production costs Rs.6,00,000 Rs.6,00,000
Fixed Marketing costs Rs.1,00,000 Rs.1,10,000
Fixed Distribution costs Rs.1,40,000 Rs.1,20,000
Fixed customers service cost Rs.8,50,000 Rs.15,00,000
Total Rs. 16,90,000 Rs.23,30,000
Year 2 Year 3
Variable Production costs / unit Rs.35 Rs.37
Variable Marketing costs / unit Rs.7 Rs.8
Variable Distribution costs / unit Rs.3 Rs.2
Variable Customers service cost / unit Rs.2 Rs.3
Rs.47 Rs.50
The labour cost is included in production costs. Production of one unit requires 2 hours of
labour. Labour cost is Rs.10 per hour in year 2 and Rs.12 per hour in year 3.
Ignoring time value of money, (i) Find the Selling price per unit if the mark is 20% of the
Life cycle cost per unit.
(ii) Assume that a learning of 95% is expected to occur until the 128th unit has been
completed; find the revised selling price unit, the mark-up percentage remaining
unchanged.
Answer:
(i) Determination of selling Price
Costs of year 1 Rs.28,80,000
Year 2 : FC Rs.16,90,000
Year 3 : FC Rs.23,30,000
Year 2 : Variable cost (80,000 units @Rs.47) Rs.37,60,000
Year 3 : Variable cost (2,20,000 units @Rs.47) Rs.103,40,000
Total Life cycle costs Rs.2,10,00,000
Life cycle Output 3,00,000 Units
Life cycle costs per unit Rs.70
Selling Price Rs.70 + 20% = Rs.84.
(ii)
20
Q. No. 15.21 A factory has a special offer to produce 4 units of a labour intensive product by
using its existing facilities after the regular shift time. The product can be produced by
using only overtime hours which entails normal rate plus 25%, so that usual production is
not affected. Two workers are interested in taking up this additional job every evening
after their usual shift is over. One is an experienced man who has been working on a
similar product. His normal wage is Rs.48 per hour. The other worker is a new person who
earns Rs.42 an hour as normal wages. He can be safely considered to have a learning curve
of 90% for this work. The company wants to minimize the Labour cost for the order. Only
one person is to be chosen for the job. The experienced man take 20 hours for the first unit
while the new worker will take 30 hours for the first unit. Evaluate who should be chosen
for the job. (CA Final Nov 2010)
Answer
Time requirement by new worker
No of units produced Average time (Hours)/ unit Total time (Hours)
1 30 30
2 27 54
4 24.30 97.20
(ii) A new type of machinery is to be installed in the factory. This is patented process
and the output may take a year for full fledged production. The factory manager
wants to use a learning rate on the workers at the new machine.
(iii) An operation uses contract labour. The contractor shifts people among various jobs
22
once in two days. The labour force performs one task in 3 days. The manager wants
to apply an average learning rate for these workers.
You are required to advise to the manager with reasons on the applicability of the learning
curve theory on the above information. (CA Final Nov. 2009)
Answer
(i) The learning curve is not applicable on experienced people.
(ii) Learning rate is not applicable to a new process as the firm has no past data
required for this purpose.
(iii) The learning curve is applicable when labour turnover is zero. In this labour
turnover is there, learning curve is not applicable.
Q. No. 15.23 A company has designed and produced a prototype electronic starter for
which the following information are available:
Direct Direct Direct Labour Variable Fixed
Labour Material Rate Overheads Overheads
260 hours Rs.30,000 per unit Rs.20 per hour 130% of Labour 70% of Labour
Based on the demonstration of Prototype, the company has received order for 50 units
during first six months and another 75 units order for next 6 months.
Learning curve is 80%. It is expected that a discount of 5% on materials will be available
for first six months and 10% for next six months. The rates of overheads will remain
unchanged and the same percentages would apply. The company sets the selling price
with a 40% mark up on costs. Determine the selling price per unit for first 50 units and
next 75 units. (The index of learning curve rate effect of 80% is 0.3219)
[ICWA Final Dec. 2002]
Answer
First 6 Months
Y = axb
Y is the average time per unit for x units.
a is the time for the first unit.
x is the cumulative number of units
b is the learning coefficient
Y = 260(51)– 0.3219
Log Y = Log 260 – 0.3219Log51
Log Y = 2.4150 – 0.3219(1.7076)
Log Y = 2.4150 – 0.5497 = 1.8653 Taking Antilog on both sides, Y
Total time for 51 units (1 unit is prototype required for demonstration and 50 units are
required for customers) = 51 x 73.33 = 3740 hours
23
Answer
First 20 units
Y = axb Y is the average time per unit for x units.
a is the time for the first unit. x is the cumulative number of units
b is the learning coefficient
Y = 400(21)– 0.3219
Log Y = Log 400 – 0.3219Log21
Log Y = 2.6021 – 0.3219(1.3222)
Log Y = 2.6021 – 0.4256 = 2.1765 Taking Antilog on both sides, Y = 150.2 hours
Average time per unit if 21 units are produced = 150.2 hours
Total time for 21 units (1 unit is required for demonstration and 20 units are required for
customers) = 21 x 150.2 = 3154 hours
Total time for first unit (demonstration) = 400 hours
Total time for 20 units for customers = 3,154 – 400 = 2754 Hours
Next 30 units (Over 21 units)
Y = 400(51)– 0.3219
Log Y = Log 400 – 0.3219Log51
Log Y = 2.6021 – 0.3219(1. 7076) = 2.0524
Taking Antilog on both sides, Y =112.8 hours
Average time per unit if 51 units are produced =112.8 hours
Total time for 51 units = 112.8x 51 = 5752.80
Total time for 21 units = 3154
Total time for additional 30 units = 2,598.80 hours
Time per unit (on additional 30 units) = 2598.80/30 = 86.63 hours
Y = 400(81)– 0.3219
Log Y = Log 400 – 0.3219Log81
Log Y = 2.6021 – 0.3219(1.9085) = 1.9878
Taking Antilog on both sides, Y =97.23 hours = Average time per unit if 81 units are produced.
Total time for 81 units = 97.23 x 81 = 7875.63
Total time for 21 units = 3154
Total time for additional 60 units = 4721.63 hours
Calculation of Selling Price for each of two lots
First lot of 20 units Second lot of 60 units
Materials @ Rs.18,000 per unit 18,000 18,000
Wages per unit 3,443 1,967
25
Effect of cancellation
For 30 units, Labour per unit should have been charged : 2,166
Fixed overheads per unit should have been : 2,707 4873
For 60 units, Labour per unit has been charged : 1,967
Fixed overheads per unit has been : 2,459 4426
Under recovery of cost : 30 x (4873 – 4426) = Rs.13,410
Q. No. 15.25 Dynamo, a manufacturer of aircraft parts, has been asked to bid for 900 units
for a particular type of component. The company has completed a first lot of 400 units
for another customer. The cost details of this first lot are given below:
Rs.
Direct materials 30,00,000
Direct labour 8000 Hours 20,00,000
Tooling cost 4,80,000
Variable overheads Proportional to direct labour 9,00,000
General overheads Proportional to direct labour 12,00,000
Total 75,80,000
Repeated assembly of this type of component experiences a learning effect of 85%. The cost
benefit of this will be reflected in the bid Price. Dynamo follows a policy of setting the
selling price to earn 30% profit. Tooling costs have been fully recovered from the first lot
sold. Determine the selling price per unit for the second lot indented.
[ICWA Final Dec. 2001]
Answer
Let 400 units = 1 Batch
Y = 8000(3.25)– 0 .2346
Log Y = 3.9031 – 0.2346(log3.25)
= 3.9031 – 0.2346(0.5119)
= 3.7830
Y = 6067 = average time per batch if 3.25 batches are produced.
Total time for 3.25 batches = 19,718 hours
Total time for first batch = 8,000 hours
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Calculation of selling Price per unit for the second order of 900 units
Rs.
Material (30,00,000/400) 7,500
Labour ( 13.02 hours @ Rs.250) 3,255
Variable Overheads (45% of Labour) 1,465
Fixed Overheads ( 60% of Labour) 1,953
Total cost 14,173
Profit (14,713 x30/70) 6,074
Selling Price 20,247
15.1-3 ASSUMPTIONS
Some assumptions of Learning curve
(i) The task is repetitive.
(ii) The task is labour intensive. (The concept of learning curve does not apply to
the automated operations).
(iii) Workers are motivated.
(iv) Labour turnover is nil.
(v) The production is continuous, i.e., there are no extensive breaks.
(vi) The worker is not well experienced in the field.
(vii) Constant rate learning
(iii) Life-cycle costing: Product life cycle costing considers the effect of learning for
accurate estimates of the costs.
(iv) Standard cost: Standard cost for different production levels should be
determined considering the learning effects.
(v) Bid for contracts: correct bids can be submitted for the contracts on
consideration of learning effects.
Theoretical Questions
15.1T State the areas in which the application of learning curve theory can help a
manufacturing organization. (CA Final May 2003)
Answer: Please refer to paragraph 15.1-5.
15.2T What are the distinctive features of learning curve theory in manufacturing
environment? Explain the learning curve ratio. (CA Final Nov. 2007, Nov. 10, Nov. 2012)
Answer: Please refer to paragraphs 15.1-4 and 15.1-1.
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15.3T What are the limitations of Learning curve theory? (CA Final Nov. 2011)
Answer: Please refer to paragraph 15.1-7.
15.4T Explain the concept of learning curve and discuss its relevance to pricing decisions.
(CA Final May 2004)
Answer : Please refer to paragraph 15.1-1 and 15.1-6.
15.5T Explain the concept of Learning curve. How can it be applied to cost Management?
(CA Final May 2006)
Answer : Please refer to paragraph 15.1 and 15.1-5.
15.6T Briefly explain the learning curve ratio. (CA Final Nov. 2006)
Answer : Please refer to paragraph 15.1-1.
15.7T Discuss the application of learning curve. (CA Final May 2007)
Answer : Please refer to paragraph 15.1-5.
APPENDIX
LOGARITHMS
Logarithms are of great use in calculations. They simplify typical calculations. With the help
of Logarithms, we can make such calculations which otherwise are difficult to make.
Logarithms are of two types (i) simple Logarithms (mathematically called as log base to 10)
(ii) natural log (mathematically called as natural log). In this note we shall be studying
simple logarithms.
Finding characteristic of a number less than one : In this case characteristic is negative.
Negative sign is written in the form of bar. For example -1 is written as 1 , -2 is written as 2
, -3 is written as 3 . Write the number (of which characteristic is to be determined) in
proper decimal form. In this case characteristic is number of zeros before and just after
decimal.
Characteristic ī -2 -3 -4 -5 -3 -3
Mantissa is determined using log tables. Mantissa is always positive. For determining
Mantissa decimal is ignored. Before finding Mantissa, the number (of which mantissa is to
be determined) should be reduced to four digits by approximation.
Antilog is determined using Antilog tables. The table is consulted only for Mantissa part.
Place of decimal is “characteristic plus one”. This place is counted from left hand side.
Q. No. 1: Find log of (i) 2 (ii) 56 (iii) 567 (iv) 5678 (v) 56.78 (vi) 0.543 (vii) 55556.67
Answer
log 2 log 56 log 567 log 5678 log 56.78 log 0.543 log 55556.67
0.3010 1.7482 2.7536 3.7542 1.7542 -1 + 0.7348 4.7448