What Is Backflush? Detailed Guide

Due to the scrap problem you really don’t know how many sandwiches you will need to make to get the correct quantity, so preproduction issuing would force you to go back and enter additional transactions for the scrap materials. The best option here is to use blind postproduction posting. All the operator needs to do is enter the good quantity and the scrap quantity and let the system calculate the rest. Backflushing is an accounting method that applies costs to production but can also be used to manage inventory. It is also known as “postproduction issuing.” When an operation is completed, the appropriate materials and other resources are issued against the production order. The inventory levels in the system of all components on the bill of materials are also reduced. When the inventory reaches a prescribed level, an order is placed.

  • Once the operation is completed, the operator will use a program to post the production against the operation.
  • It’s not so aggressive that it will damage the rubber gasket materials in your machine, yet it is efficient enough to readily dissolve accumulated coffee oils.
  • You would also have options to change individual item quantities and add individual scrap quantities to detail lines.
  • It is also known as “postproduction issuing.” When an operation is completed, the appropriate materials and other resources are issued against the production order.

When you create a production order you will usually enter some very basic information such as item number, requested quantity, and requested date . This information is then used to create the materials list and the routing for this specific production order.

Meaning Of Backflushing

If the materials list did not specify the locations the materials were to be picked from, you would have to enter that detail information before completing the transaction. The program will probably also have an option to increase or decrease the entire materials list at the header level by changing the quantity required of the finished item; all detail lines will then recalculate based on this quantity. You would also have options to change quantities on individual detail lines or only issue individual detail lines. Backflush accounting is inappropriate when production process is long and this has been attributed as a major flaw in the design of the concept. It may also be inappropriate if the bill of materials contains not only piece goods but also many parts with more or less variable consumption. Difficulties maintaining correct inventories on shop floor may also appear if it is usual practice to use alternative materials and/or quantities without needing derogation. Thus, variances in consumption, in comparison to the standard bill of materials, are taken into account and assigned to the correct product, production order and workplace.

When you are using bulk materials such as bar stock, roll stock, sheet goods, and dry goods or liquids in bulk containers, where the exact quantity cannot be picked. In very long production runs where preproduction posting takes the materials out of the on-hand inventory balance days or weeks before they are being used and puts the dollar value into a WIP account. Anyone that has tried to rectify WIP accounts will tell you that the less you have in the WIP account and the quicker things come out of the WIP account the better off you are. It’s far easier to track inventory than WIP (seearticle on Work-In-Process ).


Usually the first approach is used for materials which are piece goods. If the materials are not piece goods , then the workplace has to report the consumed quantities after it has finished its job on a particular production order. If a process control system is being used then the process control system will report the consumed materials directly to the ERP\MRP- System or to the MES and then the MES reports to the ERP.

Backflush accounting is employed where the overall business cycle time is relatively short and inventory levels are low. A cellular device manufacturer wants to use the backflush costing method to record costs for the development of a new cellphone model. On the first day of the year, they purchase $1,000 of Component A, and $500 of Component B. The labor to assemble the phones is $1,000 over the course of the month. By using machine locations for the backflushing we essentially isolated the storage locations from the production reporting system and were able to maintain cycle counting in the storage areas. This also gave the benefit of very quickly catching production reporting errors just by monitoring the inventory at the machine locations. The bill of materials contains a complete itemization of the components and raw materials used to construct a product.

How To Combine Mes And Erp For Production

Supply Chain Management Learn about how supply chain management is all about getting the right products at the right time. Companies generally don’t know what their production scheduling systems should be able to do. Again, for a repetitive manufacturing environment involving bulk materials such as Dave says.. Backflushing often works well when production runs are long and in repetitive manufacturing environments. Using backflush costing, a debit of $2,500 to expenses and $2,500 to cash would be recorded on January 31st. The journal entry will be recorded once at the end of the production cycle. Here, it will have to calculate the exact amount of ingredients required to make one burger.


A real-world example of postproduction posting I had recently encountered was for a manufacturer of paperboard packaging materials. One of the families of products produced were round lids that consisted of a custom printed insert, rim base material, rim label material, and adhesive. The inserts were stocked on pallets of anywhere from 20,000 to 200,000 depending on size, the rim base material and rim label material were on bulk rolls, and the adhesive came in bulk containers.


Operations that have or can easily put in place automated data collection systems to accurately issue exact quantities to production orders will also have little need to consider backflushing. Backflushing is performed by operation, in the bill of material you will have to link the component to the specific operation and set the backflushing flag. You may also have to set backflushing flags on the specific operation in the routing, the program used for production posting, and at the machine/cost center level.

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What Production Planning Does With Forecast Error

Backflush accountingis entirely automated, with a computer handling all transactions. Backflush costing may not always conform to generally accepted accounting principles and also lacks consideration of sequential audit trail. You not need to activate this in MRP2 or work center screen, MRP2 screen will well defined the material components that are being backflushed. After you have completed all the cycles and the brew switch is in the off position, remove the portafilter and rinse any excess cleaning material. On our Bezzera machines, it will be the button with the “Bezzera Serpent” logo and for many machine it is simply labeled “Prog/Stop”Paddle Machines, if you machine has a brew paddle (e.g. La Marzocco) this is your brew switch.

Others preceded Ford, but Venice shipbuilding had a moving ship assembly line far earlier in history. This brings up the topic of both make to stock versus assembles to order and estimating the costs of forecast error.

Backflush Accounting

All of the raw materials are stored in random location storage in the warehouse. Material handlers would deliver rim base material, rim label material, adhesive, and inserts as needed to keep the machine running.

What is SAP backflush?

Backflushing is a method of decoupling the goods issue process from the manufacturing process. This is configured in SAP ERP when specific conditions are met which are normally present in repetitive manufacturing.

Any usage that is not in the system will throw off the numbers if it is not recorded. There are some good and bad reasons for using a backflushing system for ordering. There is little to do—when the part is shipped, the system takes care of the ordering. With the exception of Lever machines, regular back flushing is a vital part of any machine’s maintenance schedule. Not only will it prolong the life of your machine, but it will also prevent the buildup of rancid coffee oils that will make your espresso taste bitter and acrid. See our MRP and supply planning parameter setting system, the Brightwork Explorer. If you have any comments, please enter them in the message box in the lower left-hand corner, and we will add to this comment tab, and we may respond.

Backflushing In Sap Erp And Sap Apo

This is typically located on the front of the machine and reads 0-16 bar. This will come in very handy during a backflush but it is not the end of the world if you do not have one on your machine. Your brew switch is what activates the pump to make espresso.

It’s not so aggressive that it will damage the rubber gasket materials in your machine, yet it is efficient enough to readily dissolve accumulated coffee oils. The inventory turnover ratio, also known as the stock turnover ratio, is an efficiency ratio that measures how efficiently inventory is managed. The inventory turnover ratio formula is equal to the cost of goods sold divided by total or average inventory to show how many times inventory is “turned” or sold during a period. In other words, companies that adoptjust-in-timeinventorymanagement use backflush.

  • Items stored in specific locations should be transferred to the machine location when picked for production.
  • The inventory turnover ratio, also known as the stock turnover ratio, is an efficiency ratio that measures how efficiently inventory is managed.
  • Small businesses which have a rather modest variety of items in their inventory still use periodic inventory management.
  • Production runs could go from several hours to several days and would be grouped so that multiple orders using the same rim base material and rim label material were run consecutively.
  • If none of the containers is empty, no further assemblies are being produced.
  • If you configure this in routing or production order you have no need to activate this in MRP2 or Work center screen.

It’s important to note that I am assuming that if you are doing long production runs that you are posting quantities produced periodically rather than waiting until the entire run is complete. Bewilderment, fear, and sometimes repulsion are reactions you may receive when you suggest backflushing materials in a production reporting system. I recall a reaction I received when informing the new director of operations at a manufacturing plant on the details of shop-floor reporting being used which included backflushing. The reaction can best be described as one you would expect from someone experiencing his first visit to a proctologist. These reactions are usually due to confusion as to what exactly backflushing is, how it works, and when to use it. Costs are then ‘flushed’ back at the end of the production process and assigned to the goods.

You may have the person that picked the materials also go ahead and issue the point-of-use materials even though they haven’t actually picked them or you may have the operator issue these during production. You may also have situations where the amount of materials required to complete the entire production order is too large to stage at the machine all at once and smaller quantities are picked and issued as production requires. This type of transaction program and process will likely be highly prone to errors unless used with an automatic data collection system such as those using bar codes. When it comes time to start production there are several methods used to accumulate the materials required for production. One method is to simply use the materials list and pick all of the materials and transport them to the production area. You then use a program designed to issue the components to a specific production order.

What is backflushing in data warehouse?

Backflush accounting is a certain type of “postproduction issuing”, it is a product costing approach, used in a Just-In-Time (JIT) operating environment, in which costing is delayed until goods are finished.

Inversely, should a workplace report a consumption from a HU that has no book inventory in the shop-floor stock , an error is generated as a backlog in issuing the consumed materials, see chapter “Meaning of backflushing”. What kind of unplanned transactions are used to handle this error is a question of internal policy of every firm. In postproduction issuing you are not issuing the materials until production is posted against the operation. The materials may be accumulated through whatever means are most efficient for your operation.

Whenever it is time to begin the production process, there are several methods that are used to gather the required materials. One of the many methods is to used the parts-list to pick the materials from their destination and transfer them to the production area. Once this is done, the routing of all the components in the specific production order is then done by software. Backflush costing allows companies to easily assign costs to corresponding inventory. Only one journal entry needs to be made at the end of the production process to account for all costs designated to the product. Such a process saves companies time needed to record costs during the production process, which lowers accounting costs.

If you move the cam lever gasket up and down a number of times, it will redistribute the lubricant and the lever will start to move smoothly again. If it doesn’t, or if the brew lever doesn’t stay in the upright position unless you hold it there, then it’s time for you to replace and re-lubricate your cam lever gaskets. MRP2 Screen defines whether material components are backflushed are to be made at the work center. Supply Chain ManagementLearn about how supply chain management is all about getting the right products at the right time. Backflushing is not suitable for long production processes, neither for the production of customized products.

It eliminates the need for the store to close down constantly for inventory stock-taking as perpetual inventory systems allow for continuous stock-taking. Perpetual inventory systems keep a running account of the company’s inventory. Perpetual inventory systems involve more record-keeping than periodic inventory systems. These inventory ledgers contain information on cost of goods sold, purchases, and inventory on hand. Perpetual inventory management systems allow for a high degree of control of the company’s inventory by management. Perpetual inventory management is generally used by companies who have the ability to scan the inventory items.

Whenever a production order is made, only the basic information is entered which usually includes the requested quantity, the item number, and the date of delivery. This list of information is then used to create a‘parts-list’ or a ‘pick list’ as well as the routing for that specific order.


Under this system, a company records costs only after production is complete. At the end of the production process, the company assigns costs to the produced goods. This system is contrary to the standard approach, where the company records costs during production. Items stored in specific locations should be transferred to the machine location when picked for production.

Tips On Implementing Postproduction Issuing Backflushing

From a financial accounting perspective, backflushing is a technique of the perpetual inventory system. Small businesses which have a rather modest variety of items in their inventory still use periodic inventory management. A periodic inventory system does not require day-to-day tracking of physical inventory. Purchases, cost of goods sold, and inventory on hand cannot be tracked until the end of the accounting time period when a physical inventory is performed and ending inventory is compared against the sum of beginning inventory and purchases. Cost of ending inventory can be calculated by using the LIFO or FIFO inventory accounting methods, or other less common methods. The end of the accounting period is considered usually the end of each month because otherwise some taxes like the VAT cannot be charged.