Backflush - Understanding / setting
We are in the process of implementing backflush option for bulk material production consumption.
I was going thro the SAP help & some of the threads here in SCM - PP.
I could find lot of information, but I am totally lost because our team does not have any exp in implementing this.
In this situation, <u><b>may I ask the help of Experts to shed some light on this?</b></u>
<b>1. Where to start
2. What are the setting required
3. Which option to follow for backflush & pros and cons of each,</b>
Your support is greatly appreciated
Thanks in advance
Shailendra Sabale replied
Collective backflush: To facilitate backflushing, you have the option of
backflushing data collectively. You are therefore able to set various restrictions.
For example, you can backflush several materials that are to be manufactured
on the same production line.
Reporting point backflush
Reporting points are similar to the milestone logic of discrete manufacturing.
If you are working with reporting points ,you use the control key to define an operation as a reporting point operation. To do this,you select a control key, for which the Confirmations indicator in the control key is set to 1 (=Milestone confirmation).
Usually at the final backflush, all components that were installed along the
production line are backflushed. If there are greater lead times, the goods issues of
the components in the system may be posted considerably later, after the actual
In this case it is a good idea to use reporting point backflushes to make the
posting nearer the actual component backflush, after the work operations have
Reporting point backflushing enables you to withdraw components near to the
time of the operation, even when dealing with large lead times, and to calculate
the work in process. Here, you do not confirm the quantities at the end of the
production line (final backflush) but you enter the quantities produced directly
after important operations (reporting points). Reporting points are defined in the
routing. The reporting point backflush in repetitive manufacturing is similar to the
milestone backflush in discrete manufacturing (production orders). Backflushing
reporting points causes all components assigned to the backflushed reporting point
operations and the preceding operations (up until the last reporting point) to be
backflushed as well. Moreover, the system posts the production activities for the
reporting point operation and the preceding operations (up until the last reporting
point). For yields, the system reduces the components' dependent requirements of
the oldest planned order (dependent requirements are adjusted according to plan).
In the repetitive manufacturing profile, you can set the system to post the goods
receipt automatically at the last reporting point being backflushed. The master
production schedule, and therefore the capacity requirements, are not reduced until
the goods are issued. The system also updates information, for example, in the
Logistics Information System. In the mandatory reporting point backflush, you
must carry out a reporting point backflush at every reporting point (otherwise, the
system issues a warning that the backflush quantity at the missed reporting point
is less: In this case, you can specify that the previous reporting points are to be
backflushed subsequently - you do this via the Details button on the initial screen
for backflushing (Posting previous reporting points indicator). This function
subsequently posts the missed reporting point quantities). You can only execute
reporting point backflushes for the main sequence of a routing.
When each reporting point is backflushed, the backflushed quantities are
cumulated in the run schedule header per material. The quantities backflushed at
each reporting point are only reduced on backflush at the last reporting point (if
the automatic goods receipt occurs here) or on final backflush. (Only) reporting
point backflushing enables you to display "work in process" (WIP).
Prerequisites for reporting point procedure: Material master: Assign
the repetitive manufacturing profile which allows optional reporting points
(in repetitive manufacturing profile, the Reporting point backflush indicator
and the Mandatory button). In addition, the repetitive manufacturing profile
should support the activity backflush in accordance with the preliminary costing
(version-specific costing). Reason: If the routing is changed between two
reporting point backflushes (for example, available reporting point is deleted, new
reporting point is added), then the internal reporting point structures in the system
are adjusted only by a preliminary costing with the product cost collector. If the
routing changed after the last preliminary costing was created, then a warning
message is issued at the backflush and a new preliminary costing is created from
the backflush. This can also be triggered manually. Routing:: The routing must
contain more than one operation: You are required to select a control key for the
reporting point operation which contains indicator 1 (milestone backflush) in the
Backflush field. In addition, you need to assign the components in the routing to
the individual operations (Note: If you work with the final backflush only, and
not with the reporting point backflush, you do not have to carry out a component
assignment in the routing). Unassigned components are immediately deemed to
belong to the first reporting point. You must enter the routing in the material's
Errors clearing&Background processing
For errors clearing you can use COGI,bit necessary setting are required in REM Profile
If you want to use background processing,
you must also schedule the background job for separate backflushing (transaction
(RMSERI70)) in the step Define Background Job for Backflushing Processes. In
the step Define Times/Parallel Processing for Confirmation Processes, you control
on which servers/work processes the backflushing processes are carried out.
This may help you.Reward points if helpful.