Professional Documents
Culture Documents
Back Flush
Back Flush
Process
Backflush
Processing
Table of Contents
1. OVERVIEW............................................................................................................................................1
2. WHAT IS BACKFLUSHING?.........................................................................................................................1
3. WHEN DO BACKFLUSH TRANSACTIONS OCCUR?...........................................................................................1
4. PROCESS 1 : COMPLETE ASSEMBLIES AT OPERATION - MOVE TXN FORM...............................................2
5. PROCESS 2 : MOVE & COMPLETE ASSEMBLIES INTO INV.................................................................................4
6. PROCESS 3 : COMPLETING ASSEMBLIES COMPLETION TRANSACTION FORM.....................................................6
7. PROCESS 4 : RECEIVE ASSEMBLIES FROM OSP OPETRATION : PURCHASING.....................................................7
8. PROCESS 5 : WORK ORDER-LESS COMPLETIONS WINDOW..............................................................................9
9. PROCESS 6 : OPEN MOVE TRANSACTION INTERFACE : OVERVIEW...................................................................10
10. PROCESS 7 : INVENTORY TRANSACTION INTERFACE : OVERVIEW.................................................................11
11. PROCESSING MODES : ONLINE AND BACKGROUND PROCESSING (INCLUDING INTERFACE PROCESSING IN DETAIL) 11
12. BACKFLUSH PROCESSING (TYPES, RULES, GENERAL POINTS, LOT & SERIAL BACKFLUSH, RESOURCES, MISC POINTS)
............................................................................................................................................................20
13. HOW TO VIEW BACKFLUSH TRANSACTIONS..............................................................................................24
14. HOW HAS BACKFLUSH FUNCTIONALITY CHANGED OVER DIFFERENT APPLICATION RELEASES?...........................29
15. COMMON BACKFLUSH ISSUES AND HOW TO CORRECT THEM......................................................................31
1. OVERVIEW
The objectives of this white paper are to consolidate and
clarify information about backflushing and related issues.
There is no existing document which collates all the relevant
topics together. This white paper will aim to fulfill this need
and discuss the following in detail :
2. WHAT IS BACKFLUSHING?
In the Bills of Material module, when a bill is created for any
assembly, sub-assembly or a finished good, the component
supply type for each component in the bill has to be defined.
These supply types are push, operation pull, assembly pull,
Bulk, Supplier and phantom. This Bills of material is used in
Work in Process module for manufacturing the assembly/subassembly/finished good.
If the supply type of a component is Push, the components
have to be manually issued to the shop floor for the
manufacturing process.
Assembly Pull and Operation Pull components are supplied in
a different way. When a particular operation or an assembly
is completed during manufacturing,
ie during move
transactions or completion transactions, the system
automatically BACKFLUSHES components from the supply
subinventory and locator. No manual issuing of components is
required.
The term backflushes in this case refers to the process of
automatically REDUCING the component quantity from the
subinventory-locator on hand quantity when any assembly or
an operation is completed in the WIP module manufacturing
process. At the same time as reducing the inventory for the
component, the system will issue the component to the work
order .
and Assembly Pull supply types from inventory onto jobs and
repetitive schedules. Backflush transactions can be launched
by the following six different processes :
1. Completing assemblies at operations using the Move
Transactions window
2. Moving and completing assemblies into inventory using the
Move Transactions window
3. Completing
assemblies
into
Completion Transactions window
4.
inventory
using
the
Assembly Pull
Operation Pull
PUSH
Online Processing
Background Processing
11
Scrap assemblies
15
Pending
Running
Error
The
processed
move
transaction
in
WIP_MOVE_TXN_INTERFACE completes the assemblies
at an operation by moving assemblies from the Queue
or Run intraoperation step of an operation to the To
Move, Scrap or Reject intraoperation steps of the same
operation or a subsequent operation. This will then
trigger the backflush of the Operation Pull components
defined for the Operation.
Routing references must be specified for nonstandard discrete jobs. On the Discrete Job>Routing
tab, select the routing Reference when defining a
non-standard job. Routing references can be used to
create
routings
(operations
and
resource
requirements) for non-standard discrete jobs, but are
not required. You can optionally define non-standard
jobs without routings, then customize them by
21
Move
transactions
are
held
in
the
WIP_MOVE_TRANSACTIONS table.
Completion transactions are held in the MMT table.
27
28
where
where
where
where
process phase
"Backflush setup" and status="error". It will also populate the
reason why
the backflush failed.
e. The user then needs to resubmit the WMTI record after
correcting the error.
Advantantages of this functionality :
2. MTI:
The behaviour of MTI is exactly same as in base 11.5.10 i.e,
the completion fails if the backflush fails.
Important 11.5.10 patches :
There were some issues around backflush functionality after
patch 4504810 was introduced. These were resolved by
applying patch 5038886. One of the key issues resolved by
this patch was as follows :
If backflush component fails inventory validation, only the
move records
corresponding to those backflush components will fail. The
other move
records will go through.
15. COMMON BACKFLUSH ISSUES AND HOW TO
CORRECT THEM :
This section examines some of the common errors around
backflush transactions and how to correct them. It should be
noted that this section ONLY looks at issues which are related
to Backflush transactions. It does not look at all causes of
Pending Move or complete transactions. There are documents
which already cover these topics
1. Processing serial control or lot control backflush
31
negative
for
some
Inventory> On
Error : Notice that the system does not consume lots based
on lot expiration.
Cause : The standard functionality does not support FIFO
backflush based on expiration dates.
Solution : None. The standard functionality does not support
FIFO backflush based on expiration dates.
34
Error :
BF_LOT_ERROR
38