Carrying Out the Backflush 

Purpose

This process describes the process flow of backflushing in Repetitive Manufacturing. You can backflush assemblies, components and activities. You can carry out the backflush for make-to-stock REM, make-to-order REM and also for production by lots. You can also backflush actual data for valuated and non-valuated individual customer stock as well as for kanban materials.

Prerequisites

You must create a production version and a product cost collector for the production of stock materials or materials for valuated individual customer stock.

Procedure for Backflushing

  1. At the end of the production process, you access the final backflush function. The system explodes the BOM according to the following logic:
    1. If you enter a planned order, the system explodes the BOM from this planned order.
    2. If you enter a revision level and no planned order, the system explodes the BOM that is allocated to this revision level.
    3. If you do not enter a planned order nor a revision level, the system explodes the current BOM of the material using the posting date.
  2. The system posts the goods receipt of the finished material (assembly) and backflushes the components. At the same time, the system creates material documents and accounting documents.
  3. Errors can occur in backflushing. For example, there may not be sufficient warehouse stock available or important data, such as the issue storage location may be missing. You then have the following options:
    1. You can make corrections immediately in a component overview.
    2. You can set the system to post the goods issues of components with no errors only. Backlogs are created for the complete requirement quantities of the components with errors. You can then process these backlogs later. If negative stocks are allowed for the material in the storage location, the system posts negative stock quantities in certain circumstances. For more information, see: Errors in Backflushing.
  4. The system reduces the material’s planned orders or run schedule quantities by the backflushed quantity. This is done according to the strategies you set in Customizing for reducing the planned orders.
    1. The system reduces the planned orders or run schedule quantities assigned to the production version specified.
    2. The system reduces the planned orders or run schedule quantities assigned to the production version specified as well as planned orders or run schedule quantities that are not assigned to any specific production version.
    3. The system reduces the planned orders or the run schedule quantities assigned to the production version specified, those that are not assigned to any specific production version and also those that are assigned to other production versions of the material.
  5. In make-to-stock and in valuated make-to-order repetitive manufacturing, the system posts the following costs to the product cost collector:
    1. Material costs

      2. The system determines the prices of the withdrawn components from the material master records. The totaled prices are then assigned to the product cost collector.

    2. Production activities

    The posting of production activities is optional. The system determines the production costs using the standard cost estimate for the material or the preliminary cost estimate for the product cost collector.

    If the actual times differ from the planned times in the routing, you can also backflush these times. (For more information, see Correcting Activities.)

  6. If necessary, the system creates a cost log. At the same time, it updates the quantity statistics for the Logistics Information System - here it only takes actual quantities and actual scrap into account. It also updates the component consumption, the product costs and the reporting point information in the Logistics Information System.