Baan5.0b, SP13

In production order- Back-flushing of materials is set to yes. On completion of the order for the production order qty, the qty back flushed (materials) is double. Following sequence of operations carried:

1. Release production order
2. Book hrs for the individual operations & hrs processed
3. No subcon operations
4. Report-operations completed
5. System prompted to back-flush the material (quantities are available). Material back flushed
6. Production order completed

Now we find material issued is double to estimated qty.

Checkd "inventory transactions by order" in warehouse reporting and "Integration transactions by project & order" in gld. Time instance for material issue is same for all the issue transactions.

Checkd the Finished item receipt qty in inventory transaction & finance. It is same as production order qty.

Any inputs, why system triggered double qty while back flushing?

In other production orders back-flushing is in line with estimated quantities. Should we consider it as a one off case?

Thanks in advance.

gbnbabu

Hi
Just a after thought. please check the BOM unit for this item. BOM units control the qunatity required in the BOM.

Regards

bom unit is 1

Have u implemented ILC/LTC?
Check whether there is a need to run Inventory correction programs ?

Still if you dont get the solution, pls contact SSA for support. Baan is said to be strong for the manufacturing & distribution modules.

Cheers !!!

Hi gbnbabu,
Just two ideas by someone using Baan IV: what about scrap factors in the BOM? I guess you checked this already.
More likely (it happens to us already): in Baan IV you can enter a backflush quantity for each operation (tisfc010.qtbf). This entry will adjust the estimated material and therefore leads to "unexpected" backflushing quantities. I have to admit that there is no place to track the entry of this field except an audit.

Martin

Hi ravindra and Martin

Thanx for the inputs. I have checked up the following:

1. Customer site is ILC/ LTC implemented one. We have already tried out inventory correction run. However, there was no effect on financial entries. We have a long pending case with SSA Global.

2. Regarding Scrap factor - not defined. We have simulated another production order for the same manufactured item and the back flushing functionality is behaving correctly.

We shall await for SSA support inputs.

Thanx again

gbnbabu

Hi,
I faced a similar situation when i was at one of my client site.
I realized that it happened because the user changed the Production order status from "Released " to "Planned" and then released it again.(it is possible to change it only by modifying the table).
Just check,if your Problem is similar to this one

Ram

A little comment off topic: Ram's comment just pointed out how dangerous it is for users to perform GTM carelessly

Rgds,
Paul