About Backflushing Labor and Machine Hours

To backflush labor hours and machine hours, you must set the Backflush field appropriately on the Operations form. The default value displays from the work center used in the operation, but you can overwrite it for each operation for the current routing, job routing, and production schedule routing. You can specify backflushing of labor hours, machine hours, both, or neither, by operation.

Backflushing Labor Hours

When you post completed transactions, the system backflushes labor hours if the Backflush field for the operation is set to "Labor" or "Both."

Backflushing occurs automatically when you post quantities for completed transactions or report scrap. The number of labor hours backflushed is based on the quantity complete or scrapped quantities multiplied by the labor hours per piece (defined on the routing). The system does NOT consider labor hours that have been previously backflushed or manually issued.

The manufacturing type determines the routing the system uses for backflushing, as indicated by the following chart:


Manufacturing Type	Routing Used in Backflushing
Job	Job Routing
Production Schedule	Production Schedule Routing
JIT Production	Current Routing

EXAMPLE: In this example, Item XYZ has been set up to backflush labor hours. Job 100 for Item XYZ requires 15 minutes or .25/hr labor hours for each completed unit. You manually enter one hour of labor.

Later you enter a transaction for five complete units. The backflushing process automatically issues 1.25 labor hours (.25/hr x five completed units). This is in addition to the one hour that was previously manually entered, for a total of 2.25 labor hours.

On the Job Operations form, you update the Total Setup Hrs field for the operation by a manual job transaction or as a result of backflushing setup through jobs, production schedules, or JIT complete transactions. The system increases the Total Setup Cost field by the planned setup hours, multiplied by the setup rate from the operation's work center record.

The system creates material transactions and inventory journal transactions with costs from the work center record. The system creates a run job transaction or production schedule transaction each time labor is backflushed.

The following fields are updated on the Job Operations form:

Total Run Hours
Total Run Cost
Total Fixed Ovhd (Labor)*
Total Variable Ovhd (Labor)*

* If the Overhead Basis field on the Work Center form's Scheduling tab is set to include labor, the system updates these fields.

Note: The system creates a setup transaction the first time any labor is backflushed for an operation tied to a job. For production schedules, if you specified Setup Hours on the PS Item Routing, the system creates a setup transaction for every PS Release when any labor hours are backflushed.

Backflushing Machine Hours

When the Backflush field is set to Machine or Both, the system backflushes the machine hours.

Backflushing occurs automatically when you post quantities for completed transactions or report scrap. The number of machine hours backflushed is based on the quantity complete or scrapped quantities multiplied by the machine hours per piece defined on the routing. For the current transaction, the system does not consider machine hours that have been previously backflushed or manually issued.

The manufacturing type determines the routing the system uses for backflushing, as indicated by the chart shown above for backflushing labor hours.

EXAMPLE: In this example, Item XYZ has been set up to backflush machine hours. Job 100 for item XYZ requires 30 minutes, or .50/hr machine hours for each completed unit. You manually enter one hour of labor. Later you enter five complete units. The backflushing process automatically issues 2.50 machine hours (.50/hr x five completed units). This is in addition to the one hour you entered manually, for a total of 3.50 machine hours.

Material transactions and inventory journal transactions are created with costs from the work center record. The system creates a machine job transaction each time machine costs are backflushed.

These fields are updated on the Job Operations form:

Total Run Hours (Machine)
Total Fixed Ovhd (Machine)*
Total Variable Ovhd (Machine)*

* These fields are updated if the Overhead Basis field on the Work Centers form's Scheduling tab is set to include machine.