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Once ingredients are picked for a blending Work Order, they do not return to inventory at the end of a day because those ingredients may get held over to the next day to finish the work order.

The only thing that would go back into inventory is unused packaging, or Bulk Blended ingredients from a packaging BOM after the WO quantity is fulfilled.

There is a need to backflush inventory that wasn’t used for the work order, like packaging. Additionally, for inventory like ingredients, it should not be backflushed, but instead be marked as waste.

Finally, the waste should be calculated for the items that were not backflushed.

These values then would be used to populate the Yield Sheet PDF

See example values here:

...

Example Scenarios

Item Setup

  • Item = Jar 16 Ounce Salsa

    • BOM

      • Mixed Salsa

        • Phantom BOM

          • Tomatoes

          • Jalapenos

      • Jar

      • Label

  • Backflush after Work Order = FALSE

    • Mixed Salsa

    • Tomatoes

    • Jalapenos

  • Backflush after Work Order = TRUE

    • Jar

    • Label

Scenario 1

  • Produced less than work order.

  • Work Order for 10000 Jars of Salsa

  • Production Journal Output = 9995

  • No Packaging wasted.

  • Item Journal Lines:

    • Tomatoes = 10000

    • Jalapenos = 10000

    • Jar = 9995

    • Label = 9995

  • Waste

    • 5 Tomatoes

    • 5 Jalapenos

  • Backflush

  • Jar = 5

    • Label =

Components

Actual Qty

Expected Qty

Variance

Waste

Backflush

Tomatoes

10000

9995

5

5

Jalapenos

10000

9995

5

5

Jar

9995

9995

0

5

Label

9995

9995

0

5

Scenario 2

  • Work Order for 10000 Jars of Salsa

  • Production Journal Output = 9995

  • 50 Jars won’t thread

  • Before journal is posted:

    • Movement created in Goldfinch to move 45 jars from warehouse bin to input bin.

  • Item Journal Lines:

    • Tomatoes = 10000

    • Jalapenos = 10000

    • Jar = 10045

    • Label = 9995

  • Waste

    • 5 Tomatoes

    • 5 Jalapenos

    • 50 Jars

  • Backflush

    • Label =

Components

Actual Qty

Expected Qty

Variance

Waste

Backflush

Tomatoes

10000

9995

5

5

Jalapenos

10000

9995

5

5

Jar

9995+50

9995

50

50

Label

9995

9995

0

5

Scenario 3

  • Work Order for 10000 Jars of Salsa

  • Production Journal Output = 9950

  • 50 Jars cracked after filling

  • Item Journal Lines:

    • Tomatoes = 10000

    • Jalapenos = 10000

    • Jar = 10000

    • Label = 9950

  • Waste

    • 50 Tomatoes

    • 50 Jalapenos

    • 50 Jars

  • Backflush

    Label =

Components

Actual Qty

Expected Qty

Variance

Waste

Backflush

Tomatoes

10000

9950

50

50

Jalapenos

10000

9950

50

50

Jar

1000

9950

50

50

Label

9995

9950

0

50

Scenario 4

  • Work Order for 10000 Jars of Salsa

  • Production Journal Output = 10000

  • 50 Jars cracked after filling

  • Before journal is posted:

    • Movement created in Goldfinch from warehouse bin to input bin.

      • 50 Tomatoes

      • 50 Jalepenos

      • 50 jars

  • Item Journal Lines:

    • Tomatoes = 10050

    • Jalapenos = 10050

    • Jar = 10050

    • Label = 10000

  • Waste

    • 50 Tomatoes

    • 50 Jalapenos

    • 50 Jars

  • Backflush

    • None

Acceptance Criteria

Waste Object

  • Create new object with the following fields

    • Work Order

      • Lookup

    • Item Journal Line

      • Lookup

    • Item

      • Lookup

    • Base UOM

      • Lookup

    • Waste Quantity

      • Number

    • Percentage Waste

      • Percentage

    • Waste Weight

      • Conversion = Waste Quantity to Base UOM.

    • Percentage Yield

      • Formula - Percentage

        • 1 - Percentage Waste

Backflush Object (A better name may be “Backflush after Work Order”)

  • Create new object with the following fields

    • Work Order

    • Item Journal Line

    • Item

    • Item UOM

    • Backflush Quantity

    • To Bin

      • If Picking Enabled for Work Orders:

        • Then Populate with the Pick-> Warehouse Activity Line for that item → From Bin

      • If Movement

        • Then populate with the Movement → Warehouse Activity Line for that item → From Bin

    • Backflushing Complete

Batch Details

...

Work Order

  • Lookup

...

Item Journal

...

Item

  • Lookup

...

Base UOM

  • Lookup

...

Waste Quantity

  • Number

...

Percentage Waste

  • Percentage

...

Waste Weight

  • Conversion = Waste Quantity to Base UOM.

Percentage Yield

Formula - Percentage

...

Components

Actual Qty

Expected Qty

Variance

Waste

Backflush

Tomatoes

10050

10000

50

50

Jalapenos

10050

10000

50

50

Jar

10050

10000

50

50

Label

10000

10000

0

0

Item Setup

  • For Item Type = Inventory

    Add

    , add a checkbox field:

    Name:

    Backflush after Work Order

  • Type: Checkbox

    • Default = Not Checked

    • Help Text: Check this box if this item should be backflushed after a work order is completed. Do not check this box waste should be calculated for this item after a work order is completed

      .

    For Item Type = Service

    • Do not add the field.

Calculate Waste

  • WHEN a production journal is posted:

    • For each Item Journal Line WHERE Item_Backflush after Work Order = FALSE AND Item Journal Line < Work Line_Expected Quantity

      Populate the following in the Waste Object:

    • Work Order

    • Item Journal Line

    • Item

      • Base UOM

Calculate

...

Waste

...

  • Calculate the following for

    Waste_Percentage

    Waste field

    • Waste_Waste Quantity / Work Line_Expected Quantity

    For each Item Journal Line WHERE Item_Backflush after Work Order = FALSE AND Item Journal Line > Work Line_Expected Quantity

  • Populate the following in the Waste Object:

    • Work Order

    • Item Journal Line

    • Item

    • Base UOM

  • Calculate the following for Waste_Waste Quantity

    • Item Journal Line - Work Line_Expected Quantity

    • Calculate the following for Waste_Percentage

    Waste

    fieldWaste_Waste

    Quantity /

    Work Line_

    Expected Quantity

    For each Item Journal Line WHERE Item_Backflush after Work Order = TRUE AND Item Journal Line > Work Line_Expected Quantity

  • Populate the following in the Waste Object:

    • Work Order

    • Item Journal Line

    • Item

    • Base UOM

  • Calculate the following for Waste_Waste Quantity

    • Item Journal Line - Work Line_Expected Quantity

    • Calculate the following for Waste_Percentage Waste field

Waste

...

/

...

Calculate Backflush Quantities

WHEN a production journal is posted:

For each Item Journal Line WHERE Item_Backflush after Work Order = TRUE

...

Populate the following in the Backflush Object

  • Work Order

  • Item Journal Line

  • Item

  • Base UOM

Calculate the following:

Work Line_Expected Quantity - Item Journal Line_Quantity

...

Backflush

...

Calculate Batch Details

  • Populate the following fields:

    • Work Order

    • Item Journal

    • Item

    • Batch Details_Waste Quantity

      • Report Output by Routing = True

        • Work Order Quantity - Output Quantity from Production Journal for the last operation for that Work Order

      • Report Output by Routing = False

        • Work Order Quantity - Output Quantity from Production Journals

Waste/Backflush Processing

  • Create new tab on the Work Order

    • Label = Waste/Backflush

    • 3 Related Lists

      • Waste

      • Backflush

      • Batch

  • Add a new button to the Work Order

    • Label: Backflush

    • Help Description: This will backflush only the items marked as Backflush = True.

  • When the user clicks on Backflush

    • Create an item journal to move the items in the Backflush list From the input bin to the Backflush_To Bin.When the item journal is posted, update all lines to Backflush_Backflushing Complete = TRUE.