Understanding the Available Backflushing Methods and their Use for the Bike Company Scenario

You can use the Confirm Repetitive Manufacturing app to carry out the backflush and thus confirm the work progress in repetitive manufacturing.

You can also enter confirmations, also called reporting point backflushes, at each reporting point that is set as a milestone.

As a result, according to the settings in the series profile Z001 - report. Point BF/Prel.cost of the Bike Company actual costs are collected on the product cost collector when a reporting point confirmation is carried out as follows:

• The system determines the components by dissolving the current BOM and thus automatically posting the goods issue for the components consumed between two reporting points from the production storage locations.
• An automatic activity allocation is generated.
• Optionally, actual times can be posted if the actual production times differ from the times in the routing.
• Work in process (WIP) and total variances are calculated dynamically and posted in real-time to the product cost collector.
• A total cost posting can be posted at the time of the production cost backflush.
• An automatic goods receipt is posted at the time of the last reporting point backflush.
• At the end of the production process, the system posts the material costs, overhead, and production costs to the product cost collector.
• The system posts single documents for the respective postings and additionally a total document.
• Optionally, the total variance can be split into variance categories by a splitting run.

In repetitive manufacturing, assemblies, components, or operations can be backflushed.

The above example describes the production process for 10 units of the semi-finished product S11-000 - Handlebar using the backflushing method.

Operations 0010 and 0020 of the Bike Company scenario are defined as reporting points, that is, these two operations are marked as milestones in the routing.

If the confirmation type, Assembly Backflush, is selected in the Confirm Repetitive Manufacturing app, you must first enter the confirmation quantity, that is, the quantity of the semi-finished product (assembly) or the finished product, and the unit of measure.

You must then enter the material to be confirmed (assembly or finished product), the producing plant, and the production version. They describe the product cost collector.

You must then select Reporting Point. Then select the relevant operation, for example, 0010 - Cropping and Forming.

If a standard consumption with regard to material components and production activities transaction 0010 has to be posted, the Post button can be selected directly. The system then automatically posts the goods issue of the components and the default activity quantity consumptions.

If, on the other hand, you have to change the component quantities and/or activity quantities compared to the default values in BOM or routing, you must first choose the pushbutton, Post with Correction, instead of Post.

In the next screen, you can change the material input quantities compared to the default values. If necessary, you can use the Actual Activities button to change the activity type input quantities compared to the default values in routing.

Finally, select Post.

If operation 0020 - Assembly is completed at a later point of time, reporting point 0020 must be selected on the screen of the Confirm Repetitive Manufacturing app.

Then, if changes also have to be made for this operation compared to the default values of the components and/or activities, you can select the Post with Correction pushbutton again, enter the actual component values and, if necessary, click the Actual Activities pushbutton afterwards to enter the different activity values.

As part of the assembly backflush method, the correction of component quantities and activity input quantities can be carried out together for each reporting point, that is, for each operation.

The figure above shows the structure of the respective screen within the Confirm Repetitive Manufacturing app. The numbering describes the sequence of the navigation steps within the app for the example of reporting point 0010 - Cropping and Forming.