This method of keeping track of materials is known as the perpetual inventory system. By its use, it is possible to know without the taking of a physical inventory how much material is being used in manufacture and the cost of it. In this way much better control is secured over materials than under the physical inventory method. In keeping track of material values, of course, inward freight, cartage, handling and stores room cost must be loaded onto the invoice cost of the materials to arrive at the full cost at which they are issued for manufacture.
Direct and Indirect Labor
The second element of prime cost is labor. In factory accounting, labor is divided into two classes, direct and indirect. These are sometimes called productive and non-productive, terms doubtless carried over from the old economics which looked upon some labor as productive and some non-productive—necessary, it is true, but rather of the nature of a necessary evil. Direct labor is a direct cost as explained above. That is, it is the labor of the workmen who apply themselves directly to the manufactured product as distinguished from the labor of those employees who plan, lay out, and supervise the work of others. Direct labor can be definitely allocated to specific product or jobs, because it is applied directly to them. Indirect labor cannot usually be allocated to a definite product because it is applied to all the product, not being employed long enough or definitely enough on any specific product to justify keeping track of the time and charging it to specific product. Direct labor is a prime cost; indirect a factory expense. It is with direct labor that our present discussion is concerned.
The problem to be solved in accounting for labor is not the determination of the total cost of labor used, as is part of the problem of accounting for materials, but the distribution of that cost over the product. Determination of labor cost, except that accrued at any time, is a comparatively simple matter because the workmen have to be paid at regular intervals. Distribution of the labor cost over the product is more difficult. This necessitates keeping a record of the amount of time spent by each workman on specific product. In that way the labor costs can be figured quickly and distributed to the various products worked upon.
Time-Keeping Records
To keep track of the workman’s time spent on each unit of product, record must be kept by means of time cards, timekeepers, time clocks, or other similar device which will show the time at which work was commenced and the time at which it was finished or when the working force is transferred to other work. The time card is arranged with space for number or name of the jobs or products worked on and the time spent on each. Use of the hour or day rate of wages paid the workman gives the labor charge to each particular product worked upon. This time card, or its equivalent, may be kept by department foreman, a special timekeeper, or by the workman himself. At the end of the week or other period, these time cards are turned into the office and they serve as the basis for making up the past week’s pay-roll or as a check against the pay-roll where some other source for the make-up of the pay-roll is used.
Pay-Roll
The pay-roll is merely a list of the names or numbers, or both, of the workmen, showing the time employed during the past period, and the rate of wages. A column to carry total amount due each workman is provided, as well as in some cases a place for the signature of the workman’s name to acknowledge receipt of payment. Provision may be made for other information, also, such as distribution of the labor cost to the specific product, but this is not usual. When the time cards of the workmen are turned in, they are checked against foremen’s reports or sick notices. The total time spent by each workman multiplied by the rate of wages gives the amount earned by each man. From this may be deducted any claims, such as insurance, rent, store charges, hospital and sick benefit, giving the net amount due the workman.
Safeguarding the Pay-Roll
Since the pay-roll is such a frequent source of error and fraud, all possible safeguards, chiefly of an internal sort, should be made use of. Where possible, workmen should be employed through an employment department to which requests for men needed should be sent. Some form of card record should be kept for office files of all men taken on—and perhaps of all men interviewed. Additions of names to the pay-roll should not be allowed without authorization, and the payment of the men should not be made by the same clerks who make up the pay-roll. The pay-roll should be checked as to mathematical correctness and, where possible, as to the content of the roster, both before and after making payment. Too often has the total of the pay-roll been changed after its correctness has been proven but before it has been presented to the treasurer to provide the funds needed, the thief pocketing the difference between the amount needed for payment of labor and the raised amount of the pay-roll. Checking before and after payment will prevent this.