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Microlesson · 5-min read

Capacity Concepts and Treatment of Idle Capacity Costs

## Types of Capacity

### 1. Installed / Rated Capacity

  • Maximum theoretical capacity based on technical specifications
  • Also called theoretical capacity
  • Not achievable under normal operating conditions (assumes 24×7 with zero downtime)

### 2. Practical Capacity

  • Installed capacity minus normal unavoidable losses (repairs, maintenance, idle time, holidays)
  • Also called operating capacity or net capacity
  • Generally 80–90% of installed capacity
  • Used as the base for determining overhead rates in practice

### 3. Normal Capacity

  • Average output achievable over several periods under normal conditions
  • Adjusts for planned maintenance and routine time losses
  • Smoother than actual capacity; used for standard cost setting

### 4. Actual Capacity

  • Capacity actually achieved during a given period
  • Expressed as a percentage of installed capacity
  • Fluctuates period to period based on actual orders and operations

### 5. Idle Capacity

  • Capacity that cannot be effectively utilised
  • Two types:
TypeFormulaCause
Normal Idle CapacityInstalled Capacity − Normal CapacityInherent in operations (planned maintenance, holidays)
Abnormal Idle CapacityNormal Capacity − Actual Capacity (when actual < normal)Lack of demand, material shortage, labour shortage

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## Treatment of Idle Capacity Costs

TypeTreatment
Unavoidable Idle CapacityUse a supplementary overhead rate; charge to capacity actually utilised
Avoidable Idle Capacity (faulty planning, power failure)Write off to Costing Profit & Loss Account
Seasonal Idle CapacityInflate overhead rates to spread cost over productive output

> Key principle: Normal/unavoidable idle capacity costs are a product cost (absorbed via overhead rates). Abnormal/avoidable idle capacity costs are a period loss (written off to P&L).

Worked example

### Example 1

Capacity calculations:

Installed capacity = 10,000 units/month

Normal capacity = 8,500 units/month (accounts for planned maintenance)

Actual capacity this month = 7,800 units

  • Normal Idle Capacity = 10,000 − 8,500 = 1,500 units (routine/inherent)
  • Abnormal Idle Capacity = 8,500 − 7,800 = 700 units (due to shortage of materials)

Overhead rate based on practical capacity (≈ 9,000 units): ₹4,50,000 / 9,000 = ₹50/unit

Overhead absorbed = 7,800 × ₹50 = ₹3,90,000

Actual overhead = ₹4,50,000 → Under-absorption = ₹60,000

Of the ₹60,000: normal idle portion → supplementary rate or carried in product cost; abnormal idle portion (700 × ₹50 = ₹35,000) → charged to Costing P&L.

⚠️ Common exam mistakes

  • Confusing normal idle capacity with abnormal idle capacity – normal idle is built into the system (planned); abnormal idle is a variance that should be investigated.
  • Using installed capacity as the base for overhead rates – this creates persistent over-absorption since installed capacity is never achievable; use practical capacity instead.
  • Treating all idle capacity costs as a product cost – avoidable idle capacity costs (e.g., caused by faulty planning) must be written off to P&L, not loaded onto products.
  • Forgetting that seasonal idle capacity gets a special treatment (inflating overhead rates) rather than being written off to P&L.
Reference:
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