Waste / Backflush Tab on Work Order
- Becky Christiansen (Unlicensed)
- Scott Zhuo
- 1 Business Need
- 2 Example Scenarios
- 2.1 Item Setup
- 2.2 Scenario 1
- 2.3 Scenario 2
- 2.4 Scenario 3
- 2.5 Scenario 4
- 2.6 Item Setup
- 2.7 Calculate Waste
- 2.8 Waste/Backflush Processing
Work Order type
Batch work order
Batch sizes
Depending on the weight of the products…
Pack out work order
Output of work order
jar
label
Allocation/Pick Ticket/Replenishment Movement
Replenishment Movement with overage %
Record Item No, Lot No, Waste Qty,….User Id, starting date/time, ending date/time
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:
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.
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.
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
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
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 a checkbox field: Backflush after Work Order
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.
Calculate Waste
Waste_Percentage = Waste Quantity / Expected Quantity
Waste/Backflush Processing
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.