Material Issue Method
The 'Issue method' field indicates when and how material issues to work orders and manufacturing orders are reported.
This table shows the different issue methods and their descriptions:
| Alternative | Description |
|---|---|
| 1 | Material is issued against a picking list according to the allocation method used. Note that this method should be used if the item is order initiated. |
| 2 | Material is issued against a requisition and reported manually. |
| 3 | Material is issued automatically based on the quantity reported as put away. The issue is always made from the location entered per item/warehouse. |
| 4 | Material is issued automatically based on the quantity reported as produced in the operation where it is used. The issue is always made from the location entered per item/warehouse. |
| 5 | Material is issued automatically based on the quantity reported as put away. The issue is made from the location entered in the work center for the operation to which the material is connected. |
| 6 | Material is issued automatically based on the quantity that is reported as produced in the operation where it is used. The issue is made from the location specified in the work center for the operation to which the material is connected. |
| 7 | This option is set to exclude the issue of the bulk item for child process or pack orders in 'Manufact Order. Report Issue' (PMS060). |
| 8 | Material is reported in one manufacturing order and issued to the next order by an external manufacturing execution system. |
| 9 | Material is issued automatically by an external manufacturing execution system. |
| 0 | Material issue method 0 may be used for non-stocked items for work orders in 'Work Order. Reschedule' (MOS010). The material transaction status is set to 90 as soon as the transaction is made. |
Issue methods 3 to 6 issue material without an availability check. A negative on-hand balance occurs if the issued quantity is greater than the on-hand balance.
When you use method 5 or 6, the work centers to which the material is connected must be set as item location issues on 'Work Center. Open' (PDS010/F). Otherwise, the issue method automatically resets to 3 or 4 for created manufacturing orders.
Allocation Location
Catch weight backflush
The 'Catch weight backflush' parameter is added to 'Product. Connect Materials/Operations' (PDS002/E) and 'Manufact Order. Open Lines' (PMS101/E). The field is only visible if the product is a catch weight item. If the field is activated, the received catch weight is used to calculate the issue quantity and weight in the backflush routine.
These two scenarios that handle the received catch weight differently:
-
The component marked as 'Catch weight backflush' isn't a catch weight material.
The issued quantity equals the received catch weight plus any additional issue for scrap and waste.
These are the consumption calculation rules:- Consumption caused by scrap is calculated based on the received quantity.
- Consumption caused by waste is calculated based on the total used quantity.
This is an example of consumption calculation:
A product with basic unit "Box", catch weight unit kg. 1 Box = 2 kg
The product structure has material with catch weight backflush, quantity 2 kg with 5% waste.
The operation the material is connected to have 5% scrap
A manufacturing order is reported, 500 Boxes received, Catch weight 1005 kg. The backflushed quantity will be: Manufactured quantity, including scrap = 500/0,95= 526 boxes
Issued quantity due to scrap = (527 - 500) * 2 = 53 kg
Issued quantity, excluding waste = 1005 + 53 = 1058 kg
Total backflush quantity, including waste = 1058 * 1,05 = 1111 kg
-
The component marked as 'Catch weight backflush' is a catch weight material.
The issued quantity follows the normal backflush logic.
The issued catch weight is controlled by the received catch weight. The difference between the received catch weight and the calculated received catch weight is added to the calculated issued catch weight.
Calculated received catch weight (CCW) = Received quantity * catch weight conversion factor Received catch weight (RCW) = Reported weight in the receiving transaction. Deviating catch weight (DCW) = RCW - CCW
This is an example of product catch weight u/m = material catch weight u/m:
A product with basic unit "BOX", catch weight unit kg. 1 Box = 10 kg
A material with basic unit "PCE", catch weight unit kg. 1 PCE = 2 kg
The product structure has material with catch weight backflush, quantity 2 PCE
A manufacturing order is reported, 10 Boxes received, Catch weight 110 kg. These are the backflushed quantity:
Manufactured quantity = 10 boxes, Catch weight 110 kg
DCW = 10 kg (110 - 100)
Issued quantity = 10 * 2 = 20 PCE
Issued catch weight = (20 * 2) + 10 = 50 kg
This is an example of product catch weight u/m <> material catch weight u/m:
In this scenario, we must convert the received catch weight to the material catch weight. For the material, the product catch weight u/m must be added as an alternate u/m.
A product with basic unit "BOX", catch weight unit kg. 1 Box = 10 kg
A material with basic unit "PCE", catch weight unit hg. 1 PCE = 20 hg, alternate unit kg, 1 PCE 2 kg
The product structure has material with catch weight backflush, quantity 2 PCE
A manufacturing order is reported, 10 Boxes received, Catch weight 110 kg.
The backflushed quantity will be:
Manufactured quantity = 10 boxes, Catch weight 110 kg
DCW = 10 kg (110 - 100)
DCW in material catch weight u/m = 10 / 2 = 5 (DCW in basic u/m), 5 * 20 = 100 hg
Issued quantity = 10 * 2 = 20 PCE
Issued catch weight = (20 * 20) + 100 = 50 hg
Limitations
These are the limitations of 'Catch weight backflush':
- The material engineering unit of measure must be the same as the products catch weight unit of measure.
- Only one piece of material in the product structure can have catch weight backflush active.
- 'Catch weight backflush' can only be used for issue methods 3 and 5, that is issues based on manufacturing order receipt.
Aggregated backflush
In a manufacturing environment where the quantity of manufacturing orders (MOs) is high and the MOs are reported frequently, many stock transactions are created. This occurs when the MO has many backflush material lines. For each material line, a stock transaction is created each time the MO is reported, including operations and stock receipts. This process causes the stock transaction history to grow rapidly.
To reduce the number of stock transactions, you can report aggregated backflush issues instead of separate issues. To get aggregated backflush, the 'Aggregated backflush' parameter in 'Manufacturing Order. Open' (PMS100) must be activated. If this parameter is set, all backflush issues are accumulated per issue method until the backflush issue is started.
The 'Aggregated backflush' parameter has these values:
- 0 - Detailed backflush: Each transaction creates a separate backflush issues.
- 1 - Aggregated backflush: Each transaction is summed, and the backflush issues are created periodically. Periodic issues are created when you run 'Manufact Order. Activate Backflush Issue' (PMS998).
- 2 - Aggregated backflush and automatic MO close: This value is the same as option 1, but when the MO is finished, marked, and all operations are reported, all pending aggregated backflush issues are activated.
Even if 'Aggregated backflush' is selected, you can still have a detailed specific material line per MO transaction. To do this, you must select the 'Detailed backflush' parameter in (PMS101). This parameter is visible only for the orders where 'Aggregated backflush' value is 1 or 2.
If you select 'Detailed backflush' for a material line, the backflush issues are created per reported MO transaction in (PMS998).
In (PMS998), you can include all pending backflush issues or only aggregated backflush issues. To include only aggregated backflush issues, specify 'Aggregated' before submitting the job. All pending backflush transactions are always issued during the system maintenance run.