Backflushing Assembly Parts and Hours

If you do not want to record every issue of a material or every spent production hour individually, you can apply backflushing instead. Backflushing saves time, but some precision is lost. Typically, backflushing is used for low-cost material with a regular consumption. Backflushing does not reflect the physical material flow, but is an administrative process. Backflushing can be defined as the automatic issue of materials from inventory, or accounting for the hours spent on manufacturing an item, based on theoretical usage and the quantity of the item reported as complete.

For more information, refer to Assembly backflushing.

To backflush the assembly parts and hours, complete these steps:

  1. Select your assembly line. Click Assembly Part Requirements > Backflush Requirements... on the appropriate menu. The Backflush Requirements (tiasc7241m000) session starts.

  2. Click Backflush to start the backflushing process.

  3. When the backflushing process is successful, LN sets all the line station orders related to assembly orders to the Closed status. The assembly orders have the Completed status.

Closing assembly orders

  • Prerequisites

    You can close assembly orders only if the following conditions are met:

    • The status of the assembly orders must be Completed.
    • All line station orders that are linked to the assembly orders must have the status Closed, that is, these line station orders must have been backflushed. Refer to the Backflush Requirements (tiasc7241m000) session.

  • Functionality

    Closing an assembly order has the following consequences, unless specified otherwise:

    • Assembly orders on supplying lines are also closed.
    • If you use Order Based transaction processing, the Assembly Orders (tiasc2502m000) session also closes the clustered line station orders of the specified assembly orders. This action results in the calculation of the results and creation of the financial transactions that are mentioned in the online help of the Close Assembly Lines (tiasc7220m000) session.
    • If the assembly order that is closed is the roll-off line assembly order, the product variant status in Line Assembly Configuration (LAC) is set to Completed.
    • LN creates the financial transactions for the closed assembly orders. LN produces error messages if the financial transactions cannot be completed. Click the Messages button to see the error messages.
    • The item surcharges are posted, and the additional calculation office variant is calculated and posted.

  • Financial transactions

    The additional calculation office variant is calculated as follows:

    Additional calculation office variant = estimated WIP + item receipt surcharges -
			 option-based standard cost.

    In this calculation, the option-based standard cost is calculated and retrieved from Line Assembly Configuration (LAC).

    The following financial transactions are posted when the additional calculation office variant is calculated and posted:

    • Transaction origin: ASC production.
    • Financial int. transaction: Additional calculation office variant.
Debit Additional calculation office variant
Credit Production WIP
  • Transaction origin: ASC production.
  • Financial int. transaction: Item surcharge (receipt).
Debit Production WIP
Credit Absorption surcharge
Note: 
  • If you use Line Station Based transaction processing, clustered line station orders are closed by the Close Assembly Lines (tiasc7220m000) session.
  • If you use Order Based transaction processing, you can reopen Closed assembly orders, that is, change the status to Completed, by booking extra hours to the orders in the People package.

To close assembly orders, complete these steps:

  1. Select assembly orders and click Close Assembly Orders... on the appropriate menu. The Close Assembly Orders (tiasc7210m000) session starts. Select assembly orders in the Selection Range and click Close Orders.

  2. If the process to close assembly orders is successful, LN sets all your assembly orders to the Closed status.

Closing assembly lines

  • Prerequisites

    You can close assembly lines by using this session only if the following conditions are met:

    • You use Line Station Based transaction processing. The Transaction Processing parameter is set in the Assembly Control Parameters (tiasc0100m000) session. If you use Order Based transaction processing, you cannot use this session because LN closes the line automatically when the assembly orders are closed in the Close Assembly Orders (tiasc7210m000) session.
    • All line station orders are Closed, which means that all line station orders for this day are backflushed.

  • Functionality

    If you close an assembly line, the following actions are performed:

    • The line surcharges are applied to the actual WIP. This action happens before the production results are calculated.
    • The results of the line are calculated and posted.
    • The clustered line station orders (CLSOs) that are linked to the line stations receive the status Closed. In Line Station Based transaction processing, a CLSO is linked to a line station per day, and this CLSO holds all the parts requirements.

  • Post-requirements

    After this session is run, you must delete unwanted data with the Purge State-dependent ASC Data (tiasl1200m000) and Purge State-independent ASC Data (tiasl1210m000) sessions.

  • Financial transactions

    The production result is calculated as follows:

    Production result = estimated WIP - actual WIP

    The financial transactions that are posted depend on whether the assembly line concerned is a main line or supplying line.

    If the assembly line is a supplying line, the following transactions are posted:

    • Transaction origin: ASC production
    • Financial int. transaction: Line surcharges
Debit Production WIP
Credit Surcharge coverage
  • Transaction origin: ASC production
  • Financial int. transaction: Production result
Debit Production WIP
Credit Production result

If the assembly line is a main line, the WIP of every order is transferred to the calculation office of the order, which results in the posting of a WIP transfer issue and receipt. In addition to the postings provided in the previous paragraphs, the following transactions are also posted:

  • Transaction origin: ASC production
  • Financial int. transaction: WIP transfer issue
Debit WIP in transit
Credit Production WIP
  • Transaction origin: ASC production
  • Financial int. transaction: WIP transfer receipt
Debit Production WIP
Credit WIP in transit
Note: 
  • If you use Line Station Based transaction processing, you can only have results per assembly line per day. If you run this session for a range of days, that is, for every day that the line surcharges are applied to the actual WIP of that day, the production results are calculated and posted for each day. The final outcome is a result that is calculated per assembly line per day, and is logged to the last line station of the assembly line. Line surcharges are applied to the actual WIP before the production results are calculated.
  • The WIP figures apply to all the line stations of all the orders on the day concerned.
  • You can reopen an assembly line by booking extra hours in People. You must then close the assembly line by using the Close Assembly Lines (tiasc7220m000) session.

You must perform backflushing successfully before the assembly lines can be closed.

To close assembly lines, complete the steps below.

  1. Select the main assembly line and click Close... on the appropriate menu. The Close Assembly Lines (tiasc7220m000) session starts. Select Close Lines on the appropriate menu.

  2. If the process to close the assembly lines is successful, all Clustered Line Station Orders (tiasc7530m000) must have the Closed status.