Waste / Backflush Tab on Work Order

Business Need

Using GoldFinch’s standard process for Daily Production Backflushing is not ideal, because it back flushes everything that hasn’t been used.

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:

Scenario Examples

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

Work Order for 10000 Jars of Salsa
Production Journal Output = 9995

Scenario 2

Scenario 3

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
  - 1 - Percentage Waste

Item Setup

For Item Type = Inventory
- Add a 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 the following for Waste_Waste Quantity
    - Work Line_Expected Quantity - Item Journal Line_Quantity
  - 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 field
  - Waste_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_Waste Quantity / Work Line_Expected Quantity

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
      - Save that value in Backflush_Backflush Quantity

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.