Re: Backflushing??? -- BPCS-L

> Subj:  Backflushing???
>  From:    lovesashi@hotmail.com (Sashikumar)
>  
>  Hi all,
>   i  don't know what is backflushing in SFC. any one can give me the answer,
>  whait it is? i don't find anything in BPCS document. help appriciated.
>  thankx
>  sashikumar

Do you want your inventory taken out of BPCS when it is issued to the folks 
who actually manufacture the parts so that WIP is not in the computer, then 
if they have anything left over, you do a transaction to add back to 
inventory what they did not use ... this approach is called FrontFlushing & 
BPCS does not support it.  BPCS has something similar to FrontFlushing called 
Allocations & BPCS does not do that very well either.  I am not 100% sure of 
the FrontFlushing terminology ... we are so lazy (translation - management 
does not want to hire a team of clerks to do what the computer can do 
automatically for us & almost as good as humans) we eagerly jumped on 
BackFlushing as soon as it became available to us.

What BPCS supports, if you want to use it, are transactions in which you 
report that you made some assembly or sub-assembly & you also had some 
quantity scrapped in the process & BPCS looks down the BOM for the part, 
which is in FMA & ELA files for SFC & JIT & concludes what raw materials must 
have been consumed to make whatever you reported ... so in one human action, 
you get:
actual cost accumulated based on labor & overhead (FOD & FLT files play a 
role here);
added to inventory receipts whatever it was that was made (good quantity);
subtracted from inventory all the raw materials needed to make what you 
reported (good + scrap down to next level of components).

The subtraction is called Back Flushing.  It is the subtraction, of materials 
input to a step of production, from inventory at the time that the so far 
production output is reported to the computer.  This approach simplifies the 
work load on humans tracking inventory activity, but it means that your total 
inventory for raw materials is always overstated by factory work that has not 
yet been reported into the computer.

One reason why you might not find Flushing in BPCS documentation is that a 
pre-requisite to BPCS education is some ERP MRP II education & I would expect 
to find Flushing in the overall ERP education.  That is, the folks doing 
documentation sometimes assume that their audience already knows the basics 
of the application they are trying to use BPCS to do, which I think is a bad 
assumption.  Many people learn BPCS on the job, and the larger ERP theory 
later.

In addition to SFC documentation, you might also look at JIT documentation.

Al Macintyre  ���
http://www.cen-elec.com MIS Manager Programmer & Computer Janitor

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