Backflush - Understanding / setting

[Former Member]

Dear All,

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

Raj

[Former Member · Accepted solution]

Hi,

First should I know on which scenario are you working?(Discrete/REM)

If discrete,you can set backflush indicators either material master or work center.If you want backflush indicators to be set in material master master, in MRP2 view in

'backflush select '1'

1 Always backflush

2 Work center decides whether to backflush.

If you want backflush indicators to be set in work center,in MRP2 view in

'backflush select '2'

These are simple settings.

For storage location determination,there is also one big logic.

The issue storage location must already have been determined for the pull list

by MRP (because the system does not take dependent requirements into account

without an entry for an issue storage location): Here, the system first searches for

the issue storage location in the BOM item of the component (Production storage

location field). If no storage location is entered in the BOM item, the MRP group

of the assembly determines whether the issue storage location from the material

master record of the component or from the production version of the assembly

is to be used (strategy for production storage location selection). This strategy

is defined per MRP group in Customizing for Repetitive Manufacturing in work

step Define Storage Location and Supply Area Determination in BOM Explosion :

Storage location = 1: The system adopts the production storage location in the

material master of the components as the issue storage location. Storage location

selection = 2: The proposed issue storage location in the production version (of

the assembly or finished product produced) is used as the issue storage location

for all components. If a proposed issue storage location has not been entered in the

production version, the system uses the assembly's receiving storage location as

the issue storage location for all components. You can define the receiving storage

location via the receiving storage location field in the production version of the

assembly, or via the issue storage location field in the material master record of the

assembly. If neither of these entries has been made, you can define the receiving

storage location at backflush in REM. This will then be used as the issue storage

location for the components. You should use indicator 2 when all components are

stored together in one storage location close to the production line where they are

required. Storage selection = 3 and Storage selection = 4: The same procedure

applies. If no MRP group has been entered for the assembly/finished product, the

system reads the entry in the Production storage location field from the material

master of the component as the issue storage location for all componen.

But generally storage location is maintained in material master.

Hope this help you.

Regards,

Shailendra

[Former Member · Accepted solution]

Dear Shilendra,

Thanks a lot for the reply. Your detailed explanation on the storage location is very useful.

1. Ours is REM scenario

2. Always backflush

3. Issue storage location set in the Material Master record - MRP2 view

After this settings

a. What are the settings req for auto GI and for financial postings

b. What are the commonly faced problems

The following is based on business / stakeholders decision. But I want your suggestion on this

1. Whether to use Final or Reporting point backflush

2. Collective backflush - how it works / settings required

3. Background processing / error clearing

I understand, it's a very long list of questions but it will help me in a great way.

Please reply

Thanks and best regards,

Raj.

[Former Member · Accepted solution]

Hi Raj,

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

physical withdrawal.

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

been completed.

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

production version.

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.

Regards,

Shailendra

[Former Member · Accepted solution]

Dear Shailendra,

Sorry for the late reply. I was on vocation to India.

Anyway your reply is very useful and informative. I will start another thread, if I encounter any issue during the course of setup and implementation.

Is it possible to provide your personal e-mail id - in case of any criticality I would like to contact you directly.

Thanks again for the detailed reply.

Raj.

[Former Member]

Are you talking about SAP bulk material ie. is it the materials which is available

directly at the work center (for example, washers or grease)?.