While using backward flushing in production order we noticed few things
- Our machine center lines are posted twice in capacity ledger entries, after changing status from released to finished it’s posting entry no 17 to 20( attached in image)
- Why does the double posting occurs for backward flush machine center only? This method is suitable if there’s no extra consumption, how can we enter extra consumption quantity in backward posting?
- In entry no 17 why the output is posted as 0 (highlighted in blue line in “image”)?
Arjun,
In this Production Order, I see 4 Routing steps. I see 4 entries where the User entered Output Quantity = 1 and no Run Time values (Quantity). What was the original Quantities for the Production Order? The Backflush shows the time Quantity being backflushed and the Output of the 1 Unit. I am OK with the Backflush of the time. What was the Item Ledger Entries for the Output?
Thanks,
Steve
Original quantity as of quantity given in header? (We gave 1 quantity in header)
We gave one quantity for all BOM components and output values.(to routings/ machine centers)
Arjun,
I see that you consumed your BOM components and they did not duplicate. Your Output is 1 unit, as seen on the Capacity entries referenced from your other pic. The Capacity booked via the Backflush of the run time you had on the routing when you changed status to Finished. All looks good to me.
Steve
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I would agree with Steve. The reason the Op 40 output was 0 is because it is the last Operation on the Production Order, and you had already Output 1. Everything looks good from the outside, how did your costing turn out?
While posting production orders using backward flush, I’ve noticed few things
When I use work center or combination of work center and machine center the process looks ok and all quantities are getting posted after changing status to finished.
However, if I use only machine centers it’s not posting last machine center from routing line. Why is it not posting the last machine center line while the status is changed to finished? Is there any setup we need to look into.
Pl check on the image which I’ve attached, the operation no 30 is not posting while order is flushed via backward flushing. If I use work center or work center/machine combo operation no 30 would have posted in capacity ledger.
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Arjun,
When you complete a Routing step do you click the Finish Box on the Output Journal or Production Journal. I check my test in CRONUS, using 3 Operations as you show, and it posted my capacity when I backflushed. Have you tested in CRONUS your example?
Thanks,
Steve
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Yes, we are checking the finish Boolean in production journal while posting but no luck. We have also recreate the issue in CRONUS and this time we have simplified two operations, we have clicked finish for both the operation while posting, but we get additional capacity line posted while finishing the order (change status). we have attached the screenshot of productional journal before posting and result in capacity entries.
Arjun
Is the last operation Workcenter or Machine set to ‘Backflush’ - if so depending on what was posted the system is trying to match postings to the Order qty - if this is the case change the last operations Workcenter or Machine to ‘Manual’ and retest.
Let us know
John Grant
Innovia Consulting
Arjun,
I just ran a quick test. When I post Output against the individual Operations, the capacity is NOT being backflushed. When I Finish (Change Status) the Production Order, all of the capacity is backflushed in the proper quantities. As long as you are not posting time to the Production Order prior to finishing, the backflush will consume the defined time required in the Routing.
Ben
Hi John & Ben,
I have tried changing the last WC to Manual it didnt help. When i changed both the WC to manual everything looks good.
I am using “Units” for Unit Cost Calculation in WC instead of Time. I tried posting individual WCs without time and finished the order still i get the First WC capacity posted again with time. What looks strange is its not posting for last WC also it posts the capacity of first WC again while finishing the order.
I am not sure what am i missing here, if you guys tested in Cronus can you post the images of BOM, routing and WC page. I will compare my settings.
I am attaching my screenshots with this.
Arjun
From your setup
You are wanting to post Direct and Overhead amounts to WIP
You are posting Output using the Production Journal
With this setup you would want to add a third operation - Work Center called ‘Output’ as an example that is setup as ‘Manual’ flushing (no time or dollars associated with the Work Center)
Also move your Routing Link code on the components to this Operation
You do not want the last Operation to be setup as ‘Backward’ as you are not interested in any automatic Output postings.
Try this setup to see if you get the desired results when you ‘Finish’ the Production Order
Best Regards
John Grant
Innovia Consulting
