Ans: Imagine you are the manager of a small factory that manufactures a popular product.
Your factory has a capacity of producing 5,000 units, and at that level, you already know all
the costs involved — raw materials, labour, power, repairs, and so on.
But now, suddenly, there’s good news! The demand for your product has gone up, and you
receive an order for 6,000 units. As the manager, your first job is to prepare a budget for
this higher production level. Sounds simple, right? But here’s the tricky part: not all costs
behave the same way when production increases. Some costs rise directly with output,
some rise partially, and some do not change at all.
This is exactly why we classify costs as variable, semi-variable, and fixed costs.
Step 1: Understanding the Nature of Each Cost
Think of costs like different personalities in your factory:
1. Variable Costs – The Flexible Ones
These costs are like friends who always “go with the flow.” If production increases by
20%, they also increase by exactly 20%. Examples: Material, Labour, Stores.
2. Fixed Costs – The Stubborn Ones
These costs are like the grumpy uncle at home who never changes his routine no
matter what happens. Whether you make 5,000 units or 6,000 units, these costs
remain the same. Example: Depreciation.
3. Semi-variable Costs – The Balanced Ones
These are like friends who partly adjust and partly stay the same. They have a
variable portion (changes with production) and a fixed portion (remains constant).
Examples: Power, Repairs, Inspection, Administration, Selling Overheads.
Once you understand these behaviours, preparing a budget is just like adjusting everyone’s
“share” when the family dinner size grows from 5,000 plates to 6,000 plates.
Step 2: Work Out Variable Portions at 6,000 Units
Now let’s calculate. Remember, 6,000 units is 20% higher than 5,000 units.
• Material Cost:
2,50,000 (fully variable) → increases by 20%
= 2,50,000 × 120% = 3,00,000