The backflushing method allows the issue of components during production based on the output quantity of the finished product. The finished product quantity is used to calculate the component quantities based proportionally on the bill of materials for one unit of finished product, plus any wastage specified in the BOM. This article assumes you already have some familiarity with the production module.
Component cost and quantity is calculated, accounting transactions are posted, and costs are distributed to the finished product when the Output tab of the production run is completed based on the quantity of output.
- Total consumed quantity for component = Finished Product quantity produced x (Component quantity per 1 Finished Product set up in BOM + Wastage quantity set up in BOM)
- The backflushing method can be used for production orders with several Finished Products, the primary finished product output will components quantity and define output quantity of the non-primary finished products.
This method considerably facilitates and speeds up the production process when there is no need for accurate inventory control. Such an approach is useful for production with relatively small cycle durations, stable consumption of components, and large BOMs for which entering actual quantities is highly time consuming.
Partial issue is not allowed and all components must be available at the shop floor location/consumption bin.
Backflushing method can be applied to entire production BOMs, components in one or more production operations, or single components. Backflushing can only be turned on at the production BOM, however, it is possible to edit whether it is applied to the whole BOM, to operations, or to components during the production run.
It can be turned on or off for individual production runs for flexibility.
NOTE: Backflushing method cannot be used at the same time as Product Tracing.
- Getting Started with the Production module (required)
- Production BOM (required)
- Managing Production Orders (required)
- Always trace must be turned off in the production settings (Settings → General Settings → Production process customisation)
- Partial issue is not allowed and all components must be available at the shop floor location/consumption bin when the output tab is completed.
Table of Contents
Configure production BOM
The component issue method defines the flow for issue of components to production. Manual method is used when components are issued manually, before production starts. Backflushing method is used for postproduction issuing of components based on the output quantity of the finished product.
Backflushing (even for a single component) cannot be used at the same time as product tracing. Product tracing must be turned off globally (via Settings → General Settings → Production process customisation) or at the production BOM level.
Backflushing cannot be applied to Co-manufacturing operations and their components.
From the production BOM tab of a finished product, component issue method can be changed between Manual and Backflush. Selecting Backflush will display a new setting so the user can decide what backflush will be applied to.
Backflushing can only be turned on at the production BOM, however, it is possible to edit whether it is applied to the whole BOM, to operations, or to components during the production run.
Backflushing method can be set for:
- the whole BOM: all components in all operations of this BOM will be issued when Production Run is completed;
- the operation: all components in this operation will be issued when Production Run in completed
- the component: this component will be issued when Production Run is completed.
Backflushing is applied to Component production BOM lines. Backflushing is not applied to Input, Output, Finished Product and Resource lines. The backflushing method set up in Production BOM can be overwritten in Production Run.
Nested products are supported. Each nested order has its own issue method set up in its BOM. Thus, when Backflushing is used, the nested products are issued the same way as any regular component.
When Backflush is applied to: Operation, a checkbox will appear on each operation of the production BOM. Checking the box will apply backflush method to that operation.
When Backflush is applied to: Component, a checkbox will appear for each component of the production BOM. Checking the box will apply backflush method to that component.
Enable/disable backflush method during production run
Production Runs inherit the backflush settings (Backflush applied to entire BOM, operation, or component) of their Production BOM, but these can be changed before production starts. The user must have released the production order and created the production run for this option to be visible.
Backflush setting cannot be changed after production has started for at least one operation of the production run. Any change of the backflush setting after production has started can only occur by undoing the production run and starting again.
backflush can't be changed when Start is pressed for at least one operation - i.e. production run starts. it can't be changes later. it remains till Complete is pressed for run. any change of the method when run is started can be done only via Undo
When backflush is applied to operation, each operation will have a checkbox to enable/disable backflush for the operation. This cannot be edited after production starts.
When backflush is applied to components, each component will have a checkbox to enable/disable backflush for the component. This cannot be edited after production starts.
Scan and Auto-consume are disabled for operations and/or components where backflush is applied. Actual Quantity cannot be entered for any components where backflush is applied - the value will be auto-filled when the production run is completed depending on output quantity.
Backflushed components cannot be edited or deleted from the loaded production BOM. Components may be added, but newly added components cannot be backflushed.
Completing the production run output with the actual output property will then calculate the proportional quantity of backflushed components. Components are issued from the Shopfloor location (if no consumption bin is added to the work centre) or consumption bin (if consumption bin is added to work centre). The entire quantity of components must be available to complete the production run, partial issue is not allowed. The user can resolve lack of components via stock adjustments, transfers or purchases if necessary.