Warehouse Movements / Warehouse Movements / Inventory Backflush (Warehouse Movements) [MOV002] and HTML / Inventory Backflush [WIP081]
In SYSPRO, backflushing enables you to receive a finished product into stock based on the bill of materials for the finished product, optionally post the relevant labor transactions, and deplete production materials inventory without using Work in Progress jobs.
This is particularly relevant when the benefits derived from creating a job to track the activity on the job floor do not justify the cost of processing all the data normally required for a job. The system uses the manufactured item's bill of materials to determine the material and labor charges to be included.
Therefore, Backflushing enables you to issue the materials from inventory, apply standard labor costs, and receive the finished goods item back into stock in one process. It is usually used in environments where repetitive production processes are manufacturing large batches of identical products, and the component usage per parent part does not fluctuate. The Backflushing transaction issues materials out of inventory after they have been physically used in the production process.
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Review BOM in SYSPRO
Let’s start by reviewing a Bill of Material (BOM) in SYSPRO.
Open SYSPRO.
From the SYSPRO Program menu, browse to Bill of Materials / Setup / Structures and Routings
The Structure & Routings screen will open.
Enter the parent stock code in the Parent stock code field or use the lookup icon to locate it.
The finished part (Parent stock code B100) comprises two assemblies, one subassembly (00B111), and one raw material item (00B112).
The subassembly part (00B111) is also made up of three separate raw material parts. (B1201, B1202, B1203)
Levels of backflushing
Two levels of backflushing can be performed from DATASCOPE PREMIUM WMS.
Single
All
The default level is All, which processes material issuance for all the stock codes under the Parent stock code of the Bill of Material.
When a subassembly (for example, 00B111) doesn’t have sufficient inventory on hand for the backflushing transaction, the software processes the component issuance one level deeper (for example, B1201, B1202, B1203) than the subassembly, and the raw materials that make up that subassembly are issued from stock. This is standard SYSPRO backflushing functionality.
However, the level of backflushing can be changed in DATASCOPE PREMIUM WMS from the default All to the Single option if you only want the DATASCOPE WMS to issue the components from the first level of the Bill of Material (for example, 00B111), regardless of the number of levels in the Bill of Material.
To update the level of backflushing, a Warehouse Setting must be changed within DATASCOPE PREMIUM WMS.
From the Ribbon Bar, browse Settings / Warehouse Settings. Select the destination warehouse and locate the INVENTORY_BACKFLUSH system name. Update the BACKFLUSHLEVEL setting value from A (All) to S (Single). Select Apply to save the change.
Backflushing in DATASCOPE PREMIUM WMS
Backflushing can either be done on a PC or a mobile device.
Backflushing on the PC screen
Open DATASCOPE PREMIUM WMS.
From the main menu, browse to Warehouse Movements / Warehouse Movement / Inventory Backflush.
Note: The Inventory Backflush module can also be found under Work In Progress / WIP Receipt / Inventory Backflush.
The Inventory Backflush screen will open.
Select the warehouse from the BF into Warehouse drop-down in which the backflush item will be receipted. (For example, FG)
Next, select the warehouse from the From Warehouse drop-down from which the component should be backflushed out of. (For example, E)
Note: A warehouse setting can be configured to enable or disable the From Warehouse. On the Ribbon Bar, browse Settings / Warehouse Settings. Locate the backflush into the warehouse from the warehouse drop-down. Locate the INVENTORY_BACKFLUSH setting and update the ISSUE_FROM_COMPONENT_WAREHOUSE setting value. The default value is N(o), which allows the user to select which warehouse it issues the component from. If this is changed to Y(es), the software will disable the From Warehouse drop-down and use the Warehouse To Use on the Bill of Material (in SYSPRO) of the parent stock code as the warehouse to issue the component.
Enter or select the Parent stock code in the Stock Code field. This is the Parent stock code you are backflushing (for example, B100)
Enter the QTY that is backflushed into the Quantity field.
The To TrackID field can be left blank. If this is left blank, DATASCOPE PREMIUM WMS will create a TrackID.
Select Post.
DATASCOPE PREMIUM WMS will validate whether the From Warehouse is a WIP Warehouse. If the From Warehouse is not a WIP Warehouse, a pop-up will appear stating that the From Warehouse must be a WIP warehouse. Change the Warehouse Setting (INVENTORY_BACKFLUSH / WIPWAREHOUSE) and ensure the select warehouse is a WIP warehouse.
DATASCOPE PREMIUM WMS classifies a Warehouse as a WIP warehouse if DATASCOPE WMS does not control the inventory within that warehouse. Any DATASCOPE WMS TrackID that enters a Warehouse configured as a WIP warehouse status is automatically changed to INACTIVATED, and DATASCOPE WMS loses control of that TrackID. This functionality is typically used when a company relies on SYSPRO to track the stock within that warehouse, usually in production environments, where using a scanning system, like DATASCOPE WMS, can make it physically challenging to control the Work In Progress material.
A Warehouse setting can be configured to mark the From Warehouse as a WIP warehouse. From the Ribbon Bar, browse to Settings / Warehouse Settings. Select the From Warehouse (for example, E) and locate the setting name INVENTORY BACKFLUSH. Update the setting value for WIPWAREHOUSE. The default is typically Y(es).
Once the From Warehouse is confirmed as a WIP warehouse, select Post.
The component will automatically be issued from the WIP warehouse. SYSPRO will control the warehouse stock, so no TrackID is required to supply the component. This transaction will only rely on sufficient inventory in SYSPRO.
Note: As the From Warehouse is configured as a WIP warehouse, any movement out of it will not be tracked in DATASCOPE PREMIUM WMS.
As the TrackID field was left blank, a printer pop-up will appear after selecting Post to print a TrackID label for the parent stock code.
Note: A printer pop-up will ask where you want to print the new TrackID labels. To print to a physical printer, you must ensure the System Settings are configured correctly and update the Printer Settings. The INVENTORY_BACKFLUSH setting under Settings / Printers on the Ribbon Bar must point to the physical printer. For more information, refer to Configure Printers.
A pop-up stating that the Inventory Backflush transaction was successful will appear, and the TrackID label will print.
Note: Ensure the correct .rpt template has been configured. From the Ribbon Bar, browse to Settings / System Settings and locate INVENTORY_BACKFLUSH in the System Name drop-down. Update the BARRELLABEL value to the correct .rpt template (DATASCOPE_TRACKID_BFLUSH_4X2.5.rpt)
The TrackID was received in the default bin defined against the To Warehouse warehouse setting. On the Ribbon Bar, browse to Settings / Warehouse Settings. Select the To Warehouse and locate the INVENTORY_BACKLUSH setting. The default bin will be visible in the DEFAULT_BIN setting value.
SYSPRO was also updated by 1 x B100 (the parent stock code) into the To Warehouse FG stock, reducing the lowest-level components from the From Warehouse SA.
The lower-level components QTYs are derived from the Bill of Material of the parent stock code and the SYSPRO transaction will be Issued.
Review the SYSPRO Issued stock.
Review the parent stock code (B100) and the applicable component (B1201) in SYSPRO to examine the stock movements.
Open SYSPRO.
From SYSPRO Programs, browse to Inventory / Inventory Query.
Enter the Stock Code (B100) into the Stock code field.
Within the Movements pane, you will notice the parent receipt that came in.
When reviewing one of the components (B1201), you will notice that components have been Issued.
Additional System Settings
An additional System setting is the AUTO_LOAD_PALLET_QTY setting, which indicates whether the pallet QTY should automatically load on the HTML5 Inventory Backflush screen.
Browse Settings / System Settings on the Ribbon Bar and locate the INVENTORY_BACKFLUSH System name. If the AUTO_LOAD_PALLET_QTY setting is set to Y(es), the DATASCOPE WMS Inventory Backflush screen will automatically populate the QTY with the Pallet quantity from SYSPRO of the To Warehouse (FG) for the parent stock code.
The default setting is N(o), but setting it to Y(es) is useful when receipting continual batches of the same QTY of the parent stock code.
The SYSPRO pallet quantity can be viewed in SYSPRO under Inventory / Inventory Query.
Enter the parent stock code in the Stock Code field.
Select the lookup icon to view the stock codes. Right-click on the parent stock code (B100) and select Warehouses.
Select the Change icon for the FG warehouse.
The Pallet Quantity will be visible.
Inventory Backflush HTML screen
The HTML5 scanner screen works like the DATASCOPE PREMIUM WMS PC screen explained in this user guide.
