Overview
"Backflushing" is a term used to describe the function of automatically issuing Component Items from Inventory to a Work Order, rather than manually entering Work Order Issue transactions. The quantity backflushed is calculated using the Work Order Component Item Quantity Per and the Quantity Booked at an operation (First Operation Backflush) or at the time of Work Order Receipt (Last Operation Backflush).
A Backflush Method must first be selected to have an Item backflush on a Work Order. The Item must be identified as a Backflush Item on the Commodity Code or the Inventory Item Master Override. Also, the On-Hand Inventory of the Item to be backflushed must be in a Location ID identified as a backflush location. When an item’s Backflush Policy is set to No Backflusing, manually entered Work Order Issue Transactions are required to issue the Work Order Component Items from Inventory to the Work Order. Therefore, on any given Work Order, it is possible to have some items backflush while others require being issued manually.
When a Work Order Demand is created, the system will check to see if the Component Item is a Backflush Item. If it is, then the Backflush Policy on the Work Order Demand is set accordingly to the Inventory Item Master record and, if not overridden, will match the Backflush Policy on the Inventory Commodity Code.
NOTE Only Items that are not serial or lot controlled can be backflushed.
Application
EXAMPLE When the Item is of low cost or when the time and effort to count and manually issue to the Work Order is costlier than the value of the Item. For example, hardware or bench stock.
Setup Location ID for Backflushing
Location ID must be indicated to be a Backflush Location
NOTE Only Location IDs from which Items will be backflushed should have the Backflush Location Indicator set.
Navigation
Inventory Location IDs
Field
Backflush Location: Check the checkbox.
Setup Components for Backflush
Backflush Last Operation
Summary
For those Work Order Item Demands that have a Backflush Policy of 'Last Operation', the system will search for the first location associated with the Component where the Item’s Location Backflush Indicator is checked and will automatically create a Work Order Component Issue Transaction, decrementing the Location quantity by the Work Order demand quantity.
NOTE An Inventory Location On-Hand Quantity cannot be negative.
If the backflush quantity is greater than the available quantity in a Location ID/Location Number, the system will search for the next eligible Location ID indicated as a Backflush Location. If no other eligible locations exist, the Item will not fully backflush.
Navigation
Inventory Item Commodity Code > Misc Tab > Backflush Policy must be set to Last Operation
OR
Inventory Item Master > Misc CC Overrides Tab > Backflush Policy must be set to Last Operation
Backflush Policy: Options are First Operation, Last Operation, or No Backflush. Set to Last Operation.
Last Operation: Items assigned with this value are backflushed (issued) from Inventory to the Work Order when the Work Order is received.
Process - Backflush Last Operation
When a Work Order Receipt is processed, Work Order Component Items designated as Backflush Last Operation will be backflushed.
NOTE When the Work Order Receipt Reversal is processed, the backflushed Work Order Component Items will be reversed to the Backflush Inventory.
Backflush First Operation
Summary
For those Work Order Item Demands with a Backflush Policy of ‘First Operation ’, the system will identify the Work Order Operation, then the Work Center. The Location ID from which to backflush is set on the Work Center Master. When an operation Quantity Booking is processed, a Work Order Component Issue Transaction, decrementing the Location Quantity, is generated.
NOTE An Inventory Location On-Hand Quantity cannot be negative.
If the Backflush Quantity is greater than the Available Quantity in a Location ID/Location Number, the system will search for the next eligible location. If no other eligible locations exist, the Item will not fully backflush.
Navigation
Inventory Item Commodity Code > Misc Tab > Backflush Policy must be set to First Operation
OR
Inventory Item Master > Misc CC Overrides Tab > Backflush Policy must be set to First Operation
Backflush Policy: Options are First Operation, Last Operation, or No Backflush. Set to First Operation.
First Operation: Items assigned with this value are backflushed (issued) from Inventory to the Work Order when Quantity Bookings are processed for any operation in the routing EXCEPT the Final Operation. If Inventory is available and Standard Operations are used, completion of the First Operation will trigger the backflush.
Process - Backflush First Operation
When a Work Order Operation Quantity Booking is processed, Work Order Component Items designated as Backflush First Operation will be backflushed.
NOTE When the Work Order Operation Quantity Booking Reversal is processed, the backflushed Work Order Component Items will be reversed to the Backflush Inventory.
IMPORTANT When the 'Operation Number' is specified for a Work Order Component, the 'Backflush Policy' field is ignored. And during Time and Quantity Booking for that Operation, the system backflushes the Work Order Component.
Backflush at Specified Operation Setup
Summary
First Operation Backflush requires that Engineering Bill of Material Master Component Item records have a Bill of Material Override Entry created for each Component designated as Backflush First Operation. This record specifies the Demand Line (user-defined), Work Center, Quantity, and the Process Number of the Operation at which the backflush of the Component is to be generated when an Operation Quantity is booked.
Navigation
Engineering BOM Master > BOM Overrides Tab
Fields
Demand Line: This number is a unique identifier for a specific Component quantity being backflushed. If multiple Demand Lines are created for a Component, the part can be backflushed at various operations, splitting the total quantity to be issued as necessary.
Work Center: The Work Center used due to this override. This works with the Process Number identified below so that the Backflush Function will be triggered when the combined Work Center and process are used.
Quantity Per: The quantity of the Component Item to be backflushed at this Work Center/Process combination. It may or may not be the entire quantity of this Item. Other amounts may be used upon the First Operation or other overrides.
Lead Time Offset: Not used in Backflushing. The number of days after the Work Order Start Date that the Component on this override record will be needed. This is used for Material Requirements Planning.
Process Number: The Process Number assigned to the operation.
Process - Backflush at Specified Operation
When a Work Order Operation Quantity Booking is processed for the specified Operation, Work Order Component Items so designated will be backflushed.
Specifying the Work Center - Issue Location
Summary
When First Operation Backflush is selected, a backflush-enabled Location ID is associated with the Work Center. This Location ID may be a Warehouse Location ID or it may be a location on the Shop Floor to which Component Inventory is moved from the Warehouse to the Work Center Location with a Location to Location Transfer.
.Navigation
Manufacturing Work Center
Field
Issue Location ID: Select the Issue Location ID associated with the Work Center. Component Items that are identified as Backflush Last Operation and which are identified in a Bill of Material Override record will be backflushed from this location.
SEE ALSO
Work Order Overview
Work Order Operation
Inventory Location IDs
Inventory Commodity Code Misc Tab
Inventory Item Master Misc CC Override tab
Engineering BOM Master
Work Order Receipt
Work Order Receipt Reversal
Time and Quantity Booking
Time and Quantity Booking Reversal
Location to Location Transfer
