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Repetitive Manufacturing: Backflushing ( RELNPP_REM_RÜCKM_30 )

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Short text

Repetitive Manufacturing: Backflushing

Description

The following new developments have been implemented for backflushing:

• Backflushing for reporting points (similar to backflushing for milestones)

Until now it was only possible to make a final backflush along with a goods receipt posting. However, a single control point at the end of the production process is not sufficient for longer lead times and several backflushing points.

In order to carry out continuous reduction of the material requirements and withdrawal of the components, the backflushing procedure at reporting points has been introduced. In this procedure, all materials are backflushed that were withdrawn and used between two reporting points. The component requirements of the oldest run schedule quantity are reduced. Costs are not determined, and capacities are not reduced until the final quantity is backflushed.

This method is also controlled via the repetitive manufacturing profile.

• Backflushing using a BOM by entering a planned order

The possibility of exploding the current BOM or the BOM of a particular revision level during the backflush has been further developed. If you enter a planned order in backflushing procedures, all the components that are allocated to the planned order are backflushed. Here, only this planned order and the corresponding dependent requirements are reduced by the backflush.

• Assembly orders

Depending on the strategy group in the material master record, the sysem either creates a production order or a planned order when creating a sales order. The planned order procedure is carried out in the form of a run schedule quantity. However, the costs are not settled via the production cost collector but directly via the salesorder (assembly order).

• Goods receipt with backflush later

It may be necessary for technical reasons, for example, to post goods receipts with no backflush and, instead, you may want to make a collective posting for the withdrawn components, for example, once the production quantity has been completed. Several new functions have been developed for posting goods receipt without backflushing. Then you carry out the backflush posting using the individual reprocessing functions.

• Collective backflush

On one screen, it is now possible to create and backflush data collectively for several materials on different production lines.

• Collective reprocessing

In the backflush, you can now reprocess discrepancies that occurred when posting the backflush collectively. To do this, you select the appropriate material number via a list.

• Entering serial numbers at goods receipt

At goods receipt, every material (as long as it is indicated that it must receive a serial number) is allocated a specific serial number. You can decide whether the number is to be allocated either internally or externally.

• Withdrawal sequence

You can control from which stocks (for example, unrestricted-use stock, and then consignment stock or vice versa) the goods are to be withdrawn in the backflush using the withdrawal sequence group that is defined in the material master record. You can define sequences for pipeline material, vendor assignment stock, and stock for unrestricted use. If several consignment stocks exist from various vendors then the system selects the one that is the cheapest.

• Alternatives

In the BOM you can group together all the materials that can be used as alternatives in the production process into one group (alternative item group). If you maintain an alternative item group, you must also maintain the following data depending on the strategy: priority, strategy, usage probability. Then in the backflush procedure, the availability check controls which materials are to be selected for backflushing. Three different withdrawal strategies exist:

• Withdrawal according to usage probability

For example, you define three alternative items (components) with similar characteristics; the first alternative item is withdrawn 50 % of the time, the second 30 % and the third 20 %.

• Withdrawal according to availability with priority

For example, you define three alternative itmes (components) with similar characteristics and define priorities in the BOM: the system first withdraws the first alternative; if there is not enough of the first one left, the system withdraws the rest from the second alternative item, and so on. The alternative items can be withdrawn in a mixed fashion.

• Withdrawal after 100 % availability with priority

For example, you define three alternative items (components) with similar characteristics and you define priorities in the BOM: the system first tries to withdraw the first component. If there is less stock available than is to be withdrawn, the system then takes the complete quantity from the second component, and so on. In this case, the alternative items cannot be withdrawn in a mixed fashion.

• Discontinued parts

In the material master record and in the BOM, you can define a discontinued parts indicator and a follow-up material or a group of parts to be discontinued. In the backflush transaction, the availability check then controls which follow-up material is to be selected for the backflush posting, once the part to be discontinued is no longer available:

• With discontinuation indicator 1, you define the main part to be discontinued. During the withdrawal, the system only monitors the stock situation of the main part to be discontinued.

• With discontinuation indicator 3, you define the dependent parts that are to be discontinued in parallel. These are discontinued along with the main part to be discontinued irrespective of their availability.
  
  

• Communication canal for bar code and BDE systems

A bar code link was created for backflushing withdrawals as well as a BDE link for backflushing from external systems.

• Backflushing actual times and costs in the CO system

By means of a pure CO function, you can backflush actual times and thus actual costs for the production cost collector. Here, you enter cost centers, activity types and backflushed times.

Damage caused to data by errors

Software/hardware requirements

Installation information

Effects on System Administration

Effects on Customizing

Reporting point backflushing

This method is controlled using the repetitive manufacturing profile in Customizing for Repetitive Manufacturing

Effect on batch input

Changes to the Interface

Changes in procedure

Procedure for removing dataset errors

Dependent functions

Planning

Further notes

PERFORM Short Reference   PERFORM Short Reference  
This documentation is copyright by SAP AG.

Length: 8177 Date: 20240523 Time: 082324     sap01-206 ( 154 ms )