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ISTech Support Forum
http://www.istechforum.com/YaBB.pl Evo-ERP and DBA Classic >> Manufacturing >> WO-I Double material issues when backflushing http://www.istechforum.com/YaBB.pl?num=1115064755 Message started by Mike_Habich on 05/02/05 at 12:12:35 |
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Title: WO-I Double material issues when backflushing Post by Mike_Habich on 05/02/05 at 12:12:35 Latest update 3/25/05 We always backflush and never issue material to WOs. Lately we've seen a couple of cases of double material issues. Two questions: --Is anyone else seeing this (in other words, is it something new)? --This can happen if the user has fat fingers...it's possible to stop partway through the Enter Finished Production procedure, start again, and thus backflush twice while producing only one output assembly. Can the program be fixed to stop this? |
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Title: Re: WO-I Double material issues when backflushing Post by wildco on 05/03/05 at 05:10:39 We have had double backflushing recently also. This seems to come when the receiver receives the parts, but then realizes there was a problem and uses the up arrow to move back up the screen to correct it. Then, when they cycle through again the backflush repeats. Another issue is that the materials stay in WIP (as shown on IN-A) until the user says Y or N as to whether or not to use STD cost. the only problem is that often users will leave their station to work on other things during the backflush (as it takes a long time on large BOMs), and mistakenly close the screen without hitting Y or N to the standard cost question. A fix for either or both issues would be much appreciated, as it would save a lot of time having to fix the records. |
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Title: Re: WO-I Double material issues when backflushing Post by Tim Keating on 05/03/05 at 07:35:45 I agree that a safeguard would be very desireable. In my experience, double issues can always be tracked to input error but it should not be that easy to make the error. As a check on this, I review all material transactions daily with an audit report I created in Crystal. For us its six or seven work order completions so its fairly manageable. For someone with a large number of daily issues it has to be a big concern. |
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Title: Re: WO-I Double material issues when backflushing Post by GasGiant on 05/03/05 at 08:18:29 Tim Keating wrote:
It is very disheartening how many of these little gotchas are in DBA. :'( SOP should be that no part of the transaction is committed until all of the transaction variables are validated. It would be better to lose the entire transaction when a problem occurs than to capture part of it and then waste time figuring out what to fix. I understand that the Serial module is separate from the inventory transaction module, but losing the one-to-one relationship between those two bits of data is a big issue in the eyes of our regulators. |
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Title: Re: WO-I Double material issues when backflushing Post by Mike_Habich on 05/03/05 at 08:38:45 This doesn't even have anything to do with serials. It's possible to backflush material without creating the assembly. On the basic idea, you're right on target. No part of the transaction shouldn't be committed until all the input is validated. This particular problem has been in DBA since at least 2000. |
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Title: Re: WO-I Double material issues when backflushing Post by Lynn Pantic on 05/03/05 at 09:06:43 There is a fundamental problem with the logic here I agree but unfortunately, the backflushing needs to be processed so that the associated component costs can be used in the calculation of the assembly cost. This is why we developed the "B" default setting in SD-B for backflushing which means "Backflush the balance needed". That way, if the backflush happens once and the transaction for Enter Finished production is not fully processed, when you go back in to process it again and it attempts to backflush, it will see that no component balances are needed and it wil not process the second backflush. |
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Title: Re: WO-I Double material issues when backflushing Post by Tim Keating on 05/03/05 at 09:07:08 Mike_Habich wrote:
I would say it's probably been an issue from the very beginning. It's one of those thing we've all lived with, having made the choice to use a low-budget but all-around pretty decent program. There are dozens of issues like this that IS Tech has addressed and fixed at little expense to subscibers. Maybe this will be another one. |
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Title: Re: WO-I Double material issues when backflushing Post by Mike_Habich on 05/03/05 at 12:44:58 Fix one problem, create another... If you change default setting to B, if you enter finished production for qty -1 (to disassemble a unit), nothing gets backflushed. |
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Title: Re: WO-I Double material issues when backflushing Post by Tim Keating on 05/03/05 at 13:55:37 Mike_Habich wrote:
I could not live with that, we teardown single items all the time. |
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Title: Re: WO-I Double material issues when backflushing Post by aricon on 05/04/05 at 05:46:02 The ultimate problem with what Mike indicated, although he is absolutely right, is that to do so requires the ability to create TEMP tables, or some such solution, during processing and then wipe that info out and transfer the data to the permanent tables. However, in the non-RDBMS environment that is DBA this is a LOT of extra programing effort and has some pretty serious potential data transfer error opportunities. |
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Title: Re: WO-I Double material issues when backflushing Post by Mike_Habich on 05/04/05 at 06:23:43 It was Colin, not me, who was "absolutely right" about the sequence of posting. I just said me too... I can certainly live with the B option of checking whether components have been backflushed, as long as negative quantities (disassembly) can be accommodated. |
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Title: Re: WO-I Double material issues when backflushing Post by wildco on 05/04/05 at 07:02:10 I agree with Mike, the B option is great, but it should have some capability for negative receipts. |
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Title: Re: WO-I Double material issues when backflushing Post by NovaZyg on 05/04/05 at 07:05:18 Ok I get the hint.. I will have a look at the - qty "B" logic. If its not to bad then it will be in the next Post.. This weekend I hope. |
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Title: Re: WO-I Double material issues when backflushing Post by Lynn Pantic on 05/05/05 at 13:10:36 OK, next update will have a change so that if the default is set to B and you are processing a negative, it will act as though the default were set to Y and prompt to backflush and if you say Y it will process negative issues of the components so you can disassemble using negative work order. We have also disabled the ESC so that once the backflush has happened, you can't get out without completing the full process. If you realize you made a mistake, you will have to go back in and process a negative. |
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Title: Re: WO-I Double material issues when backflushing Post by wildco on 05/06/05 at 05:07:38 Thank you very much, this will help immensely. |
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Title: Re: WO-I Double material issues when backflushing Post by wildco on 06/16/05 at 08:45:47 One other question on this one: We often have a BOM where we make one item, but a second product is created that is incidental to making the first one. We used to account for this by including the incidental item as a negative on the BOM, so during backflush it would be added to stock. It seems that with the new B setting, this can no longer be done. Is this a possibility to change? Otherwise, the "B" setting is perfect. |
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